This is kicking my *** and need help figuring it out.

Went to install a dynojet stage 2 yesterday and now having issues. When I removed the main jet the assembly that it screws into (part with the 8mm nut) came out with it. I turned the carb over and the little part that is farther up there fell out. When I went to reinstall the parts the entire assembly refuses to seat all the way down, sticks 1/4" further down than it should and is making the carb overflow with fuel.

 

this is the part that fell out, not my pic but its the same part
http://i56.tinypic.com/b8qyyc.jpg

I've tried reinstalling it with either end up

 

Have you tired calling Dynojet? I just got my kit in the mail (I'm doing mine tomorrow) and it says they offer support. I'd try giving them a call 800-992-4993.

 

sudco.com might have a blow up of the carb to give you an idea of what is going on... I haven't had to take the cvk carb down that far to install the dynojet kit. Make sure you check out the how to threads. I've never seen that part/What the hell is that part??

 

Is it in upside down? Or you might try a tap with a rubber or plastic hammer to seat it.

 

OEM Parts Kawasaki KLX250S (KLX250-T9F) 2009 CARBURETOR - Cheap Cycle Parts

Follow the pictures....lol Just messin' but do not force the components.

 

That looks like the jet for the needle. Try removing the top of the carb and remove the needle and then try installing the jet for the needle, the main jet holder, and the main jet. The needle may not be going into the jet which prevents the jet from seating.

Ride on
Brewster

 

finally got it all back together properly, that jet and its assembly just looks like it hangs too far down into the bowl for my liking with that main jet holder. As for the overflowing of fuel the pin that the float pivots on had almost slipped out, must have wedged with the float open and wouldnt let the needle seat to stop the fuel flow like its supposed to. carb has a 120 main jet now and so far seems to be happy just sitting here going through the rpm range, will take it for a ride in a little to test it out (letting it cool before I continue reconnecting everything since the exhaust is nice and toasty). Bike had a 118 in it and was happy with the q4 exhaust here at 2800ft, was hating life with the snorkle removed above 5500 rpms. also have the stage 2 needle on the 3rd groove now.

 

Hey Red,
Just to be clear, did the bike have the #118 stock Keihin jet, and now it has the #120 dynojet main? Main jet sizes are not the same between manufacturers. Jet Conversion Chart.

 

correct IDRIDR. the dynojet kit stage 2 calls for their 128 to be installed, with my bike it was puffing black smoke badly and flooding with that jet so I was stepping down in jet sizes until the 120 was installed. Bike runs great, need to adjust my air/fuel mix a little bit. If it idles for awhile at a stop light (30 seconds or more) I have to play with the throttle to keep it from flooding out. Also when I let off the throttle the rpm's stay up for a little while while it tries to burn the excess fuel off. Throttle cables move freely and the air/fuel screw is sitting 3 turns out, figure 1/4-1/2 a turn should make it happy.