I dont know how well JB Weld works on fuel systems. We have allways used a product called "Splash Zone" on boat fueal tanks.

You might also be able to drill the hole out larger and press fit a piece of brass rod or braiseing rod. then drill that. Look for brass rod at a hobbyshop

 

I think a plastic plug will be much easier to work with...i will be able to drill the hole before pressing the plug into the starter jet.Just not sure how far the plug actually needs to be inserted into the starter jet to work properly.I would like to just push it in far enough to be flush.

 

I don't think I would try plastic or any jb weld epoxy type stuff. I would try very hard to fix it correctly. Call / email around to see if you can get a replacement. You may be able to drill the old one out completely and press in a new one. IF you do try to use the plastic etc, test a piece of it out by soaking it in gasoline for a couple days . Make sure it wont turn to goo.
Dan

 

could try this..

2007 KLX250S Kawasaki KLX 250 carb carburetor OEM - eBay (item 170621570153 end time Apr-27-11 21:10:12 PDT)

 

Gasoline does not seem to harm plastic.

 

Depends on the type of plastic, which is why I suggested a test. I have had milk jugs get soft after keeping gas in them a few weeks. I'd still pursue every avenue I could to try and fix it correctly. Good luck with what ever you try.
Dan

 

Dan is right...all plastics are not created equal. Now that someone has snafu'd a starter jet, it would be interesting to find out if you can obtain these from some source. Those of you with factory service manuals will notice that on the carb specifications page, the starter jet and a value/size is listed in the column. Hmmmm.

 

Nylon and teflon are ok, but otherwise most plastics deteriorate fast in contact with gasoline. Same thing for rubbers, you've got to use viton or something like that.

 

Thank you for the information on plastic and gasoline.Anyone with a service manual know what size the starter jet is?

 

My book only goes to 2007, but that's probably not too important. Here's the weird thing looking all the way back to '93. They seem to bounce around from 40, 45, and 48. Might be interesting to see what the off road KLX300 had in its carb. If you could find any of these starter jets, if they're not big enough, you can still use the .018" drill bit. If one is slightly bigger, that's not going to be an issue. Some of you may remember that I drilled mine out to .020 or .022...can't remember...because we had no baseline to pick from. I think we came to the .018 by trial and error. A bigger jet just means you don't leave it on choke as long.