It doesn't seem to be a big problem.
You don't have a problem on WOT (wide open throttle) as you stated.
If it's rich on less than 3/4 throttle it's your pilot, needle or fuel screw.
You said the pilot is stock, so scratch that. Concentrate on the needle or the fuel screw.
You could have had a problem reassembling the carb'.
The only option is to take it down again and check all is as it should be.
Check the floats, if they aren't free this could cause a rich condition.
Still sounds to me like the needle isn't seated properly.
How thick was the shim you instaled?

 

This is the service bullitin, it only recomends the snorkle to be removed.

https://www.kawasakiforums.com/upfil...FD61CEBD20.jpg

And if he rejetted to the 125and is rich he should rejet back to stocknot compensate By removing the lid that makes no sense.

Ken

 

You should also checkout the thread about Keihin that I posted This has the corret info It comes from the manufacturer of the carb- the some of best tuninginformation should be in that document.[8D]( I asked for this info in a threada while back and no one responded)then there are some people who always disagree with the manufacturers...

Ken

 

"remove the rubber air intake snorkle and the top of the air box."
The service bullitin was for AUS spec bikes. They are diffeent to the USA bikes in more than 1 way.
It also says to fit a #138 main jet!
I,m trying to help diagnose the problem.
Is the bike a USA model or are you in AUS?

 

My Bad about the lid, and section 7 of that bulliten says Stock settings should be close to optimum test each bike individually some bikes may need jetting and it gave the lists for the jets it did not say to use them test first thats what it says.

Ken

 

I live in niether I wonder if there is a special canadian spec bike!! I think the guy shouldread Keihins tuning Guide that I posted That would probably help him more than any of us as well I am also trying to help. I think he should go back to stock settings read keihins info and start over and understand what he is doing, I found all the jetting info on this site to be VERY incomplete, there is Guys in AUS/canada/USA in many different climates, and what works for you in AUS probably would not work for me in northern Alberta Canada two totally different climates. Thats why keihins tuning guide would be the more logical source for info.

Ken

Ken

 

Yup!.
The stock main jet on the AUS spec bike is #134 anyway, much bigger than your #118.
Ours is essentially the KLX300R, with a 250 piston and jug.
Hence the KLX250RH7 code.
It's not the KLX250SH7 you get.



Like I said before the changes you've made are all within the ball park.
It seems have a small problem you may have overlooked. Be methodical, and run through the settings again. By all accounts it should run fine with the new settings.

Anyone else have an opinion to help out?

 

this a US bike. I can not remember the size of the shim off hand. pretty much right now is at stock setting except for up to a 125 Main. The main problem right now is it is a bitch to start. And once it dosnt start its pulling the plug cleaning and trying again. Once started and warmed up although rich it dos start pretty easy.

thanks for your guys help

 

wow wow stop right there. U have a 125 main and didnt change the pilot and are having a problem with it starting? Check this. Do u have a kouba Fuel/Air Mix screw? If so screw it all the way in and then out 2.5 and try that. If not get a screwdriver and losen the carb and turn it in and then out 2.5 and let us know if it doesnt start. ALSO CHECK UR FRONT BOOT ON THE CARB MAKE SURE IT SEALED AND IS TIGHT! And make sure u have good fuel and ur float isnt stuck and is set right!