I purchased an 06 klx250 the other day. Bike wouldn't start. Put in new battery and pulled carb. Cleaned carb used torch tip cleaners. While I had the carb in my hand it looked awfully new. I own an 04 klr250 and have gone through the carb many many times. This klx carb doesn't scream keihin to me. There are keihin jets in here. Is this some knock off amazon carb or something? I was able to get the bike running and rode it around my yard a few laps. Low gear it wanted to die on me. I will make adjustments once I know what I'm working with. I would like to have an oem carb or an upgrade. I plan on milking the 250 for everything it's got without going big bore. Thanks

 

It has a plastic slide. Someone also has been in here before as some of the jets are larger than stock. Bike was leaking fuel from overflow that comes out of bottom of carb. Adjusted the metal tang on float. Seemed to stop I will do a clear tube test when I get a chance. Triple digit heat down here in S texas really takes the motivation out of you.

 

Also the carb only has a slot for one throttle cable. The return cable was not hooked up. I heard there is a throttle sensor on the stock carb as well. I couldn't find the plug to that goes to the sensor on carb. I blocked off the smog valve and plug on air box. I know what that stuff does to engines I had on 07 6.7 cummins with egr valve and epa stuff. Really nasty stuff.

 

Looks similar to the OEM carb on my 2009 KLX, but the vacuum tube at the front for the pairs valve setup isn't there in the same place. Wouldn't surprise me if someone swapped out a carb.from something else. The 09 does not have any throttle sensor on it, nor does it have some long idle adjust setup.

I don't believe there is an overflow on the bottom of the carb, but rather it is the drain, unless there is another fitting on the float bowl. Maybe the seat is damaged if it leaks out the drain line.

If you are using welding tip cleaners to clean jets I'd venture to say you likely have damaged them, enlarging them. A friend tried drilling jets and the finish of the hole actually caused the jet to flow less run leaner. If you keep and try to use that carb I'd recommend new jets to make sure they are right. Here is a link to D Pippin's KLX250 web site that lists the jetting needed to have good performance. Click here It does show an idle adjuster and a throttle sensor, but my carb has neither one. The floats are plastic, I forget if the slide is or not.

Here is the image Kawasaki has showing:




The pairs pollution valve does nothing to the engine. It is simply a reed valve setup to allow fresh air into the exhaust to burn unburned gasses. Only effect is less unburned hydrocarbons and a bit hotter exhaust, which is not a bad thing. Hotter exhaust has higher velocity which helps, but not to any noticeable level.

 

Thanks for your help friend! I will look into finding an oem or a pumper perhaps.