How to Clean a Kawasaki KLX250 Carburetor

Kawasaki's KLX250 is a dual-sport motorcycle that may be ridden both on and off-road. Although the KLX250 has been part of Kawasaki's worldwide motorcycle lineup since 1981, it was introduced to the U.S. market in 2006. In order to make the motorcycle as simple as possible, a necessity in the face of a potential breakdown on a remote trail, the KLX250 relied on a carburetor to feed its single-cylinder engine. Unfortunately, the carburetor is prone to clogging if the fuel system is contaminated by dirt. Removing the carburetor for cleaning is a fairly straightforward task suitable for most KLX owners.

Things You'll Need

• Allen wrench, 4 mm
• Socket, 10 mm
• Socket wrench
• Open-end wrenches, 10 and 12 mm
• Pliers
• Shop towels
• Phillips-head screwdriver
• Flat-head screwdriver
• Catch pan
• Straight pick
• Container
• Carburetor cleaning solution
• Water
• Air compressor
• Blow gun

Instructions

1. Park the motorcycle on its side stand and turn the fuel valve, located under the left side of the fuel tank, to the "off" position. Let the engine cool to the touch.

2. Remove the side covers located below the motorcycle's seat using a 4 mm Allen wrench. Remove the seat grab strap using a 10 mm socket and a socket wrench. Lift the seat off the motorcycle.

3. Remove the radiator shrouds located under the front of the fuel tank using a 4 mm Allen wrench. Unscrew the fuel valve bolts from the motorcycle's frame using a 10 mm socket. Pull the fuel hose off the right side of the fuel valve using pliers. Immediately wipe away any spilled fuel using a shop towel.

4. Unscrew the bolts from both sides of the fuel tank using a 10 mm socket. Unscrew the bolt from the base of the tank using a 12 mm socket. Lift the fuel tank off the motorcycle's frame.

5. Loosen the clamps attaching the carburetor to the engine intake flange and the air box duct using a Phillips-head screwdriver. Pull the carburetor out of the air box cut, then the intake flange. Lift the carburetor out from the top of the motorcycle's frame. Loosen the throttle cable lock nut, located along the right side of the carburetor using a 10 mm open-end wrench, then pull the cable ends out of the throttle valve.

6. Hold the carburetor over a catch pan, then loosen the float chamber drain screw on the bottom of the carburetor using a flat-head screwdriver. Gently shake the carburetor until any fuel remaining in the float chamber has drained completely. Tighten the drain screw.

7. Remove the carburetor top cap using a Phillips-head screwdriver. Pull the diaphragm valve, spring and jet needle out from the carburetor. Pull the fuel hose off the inlet on the left side of the carburetor, and be sure to catch any fuel that drips out.

8. Pull the drain hose off the float chamber. Remove the float chamber using a Phillips-head screwdriver. Push the float pin out from the float towers on the underside of the carburetor using a straight pick. Pull the float and the valve needle away, then unscrew the valve seat.

9. Remove the pilot and main jets from the underside of the carburetor using a flat-head screwdriver. Unscrew the pilot screw and spring located directly under the carburetor's outlet using a flat-head screwdriver. Count the amount of turns required to remove the screw for later installation. Unscrew the choke knob from the left side of the carburetor using a 12 mm open-end wrench.

10. Place the carburetor body, float chamber, float pin, both jets and the pilot screw into a container filled with a carburetor cleaning solution. Allow the parts to soak for a minimum of one hour.

11. Rinse the parts with warm water, then clear out any remaining water or debris with compressed air applied through a blow gun. Direct compressed air into the carburetor's fuel and air passages, as well as through the jet openings.

12. Install the valve set, valve needle, float and float pin. Screw the main and pilot jets into place until they are seated against the carburetor. Screw the pilot screw and spring into place using the same amount of turns required to remove the screw. Reinstall the float chamber.

13. Push the diaphragm, spring and jet needle into the top of the carburetor. Reinstall the top cap. Screw the choke knob into place until it is seated against the carburetor. Push the fuel hose onto the carburetor fuel inlet and the drain hose onto the bottom of the float chamber.

14. Push the throttle cable ends into the throttle valve, then tighten the throttle cable lock nuts. Push the carburetor into the engine intake flange and pull the air box duct over the carburetor inlet. Tighten both clamps to secure the carburetor.

15. Place the fuel tank over the motorcycle and push the fuel hose onto the right side of the fuel valve. Screw the fuel tank bolts into place, followed by the fuel valve bolts.

16. Reinstall the radiator shrouds, seat and side covers onto the motorcycle.

Tips & Warnings

• Do not use a wire to clear the carburetor's jets. The jet openings can be widened by a stiff wire, altering fuel flow and changing the motorcycle's performance.

• Do not smoke or work near an open flame while servicing your KLX250's carburetor. Gasoline vapors are highly flammable and may ignite, causing serious burn injuries and physical damage.

References

• Kawasaki KLX250 S/SF Motorcycle Service Manual; Kawasaki Heavy Industries