Thanks guys. I read up a little last night and will continue to do so. Tonight I will delve onto the needle, and most likely post up for advice/confirmation before ordering anything.
Re: header. I used to tig quite a bit when I was younger, and do metal working projects, so I'm confident I could fix that thing. It really is an issue of time, workshop space, and tools etc now. I will make something work, it won't be too soon though !!!!!

 

Wish I knew how to TIG. I didn't do too good with wire feed, seems I could get good settings, but the flash was bright enough that, even with the hood and all, I couldn't follow where I needed to go. Maybe with more play and practice it would work better for me. But like you, it's all about time.

 

I have never messed with this kind of carb before. I will look it up, but any advise for me in terms of removing the needle? can do in frame like the twist to remove the bowl trick? Thanks!!

 

Look at the KLX250 cheap mods link. Has tips.

I don't remember if the slide can be pulled in frame, but I think it might be possible. You just have to look and try. Pulling it from the frame, the hardest part is getting the air box boot back on.

 

Yes you can pull the slide with the carb still on. I just did it. I had to rotate the carb one way to remove one bolt, then rotate the other way to remove the other 3. Just make sure your needle drops down into the needle seat before bolting the top on. It's a little tricky getting it to drop in since the carb is at an angle. Just take your time.

 

Ok, I ended up removing the tank which gave easy access to the top of the carb. I will include pictures rather than try to explain, as a lot of this carb talk still goes over my head. Let me know what you think if you will, thanks!!!!!

ETA...Im not sure the identity of this needle(stock vs DJ?) but the C clip is on the middle notch, with 3 washers stacked on top of it.

Edit#2, after looking at the pics in the "cheap mods" link in klx678 sig line, I don't think my needle is stock, the author references a n1-tc needle, that although is adjustable with notches, in the picture it has a "shoulder" that my needle does not have.

 

If I am able to confirm that the needle I have (pictured above) is in fact a DJ, then I should do as advised by Klxster and move the clip to the top notch and add two of my washers in addition to that, then resemble (carefully) making sure that the rubber diaphragm seats evenly and correctly.....
Then order jets from DJ....

 

I think that's the DN0228 needle from the DJ2152 kit. I can't tell because you left all the washers on it.. It is certainly NOT the DNO352 needle from the DJ2206 kit..

So, here, you tell me.. Left to right, DN0228, N1TC, Stock..

 

Yes, the one on the left, the DN0228. Definitely not the other two. Has 5 notches, clip is on the middle with 3 washers stacked on top. Would you agree, topmost notch, add two washer above that and reassemble?

 

Yep, with a DJ140 or a K152 (Keihin) main jet, and stock slide spring, leave off the airbox lid..

However, until you get the DJ140/K152, better put it back together as is..