Klx 250 carburetor diagram

RefPart NumberDescriptionPart, Description# On Img# Cart$ EachNotes220220AA040801 SCREW-PAN-CROS,4X8220AA040801 SCREW-PAN-CROS,4X84 on diagramx40.35220A220AA041401 SCREW-PAN-CROS,4X14220AA041401 SCREW-PAN-CROS,4X143 on diagramx32.65223223AA041601 SCREW-PAN-WS-CROS223AA041601 SCREW-PAN-WS-CROS1 on diagramx13.151104411044135301 BRACKET,THROTTLE CABLE11044135301 BRACKET,THROTTLE CABLE1 on diagramx164.351104811048181801 BRACKET11048181801 BRACKET1 on diagramx18.251309113091188801 HOLDER,NEEDEL JET13091188801 HOLDER,NEEDEL JET1 on diagramx128.601327013270106301 PLATE,FITTING STAY13270106301 PLATE,FITTING STAY1 on diagramx130.951404116005106501 TOP-CHAMBER,MIXING16005106501 TOP-CHAMBER,MIXING1 on diagramx173.001500315003007201 CARBURETOR-ASSY15003007201 CARBURETOR-ASSY1 on diagramx1667.101600716007111701 SEAT-SPRING,VALVE16007111701 SEAT-SPRING,VALVE1 on diagramx124.301600916009180301 NEEDLE-JET,N1RX16009180301 NEEDLE-JET,N1RX1 on diagramx133.751601416014108001 SCREW-PILOT AIR16014108001 SCREW-PILOT AIR1 on diagramx121.051601616016001301 PLUNGER,STARTER16016001301 PLUNGER,STARTER1 on diagramx151.351601716017101001 JET-NEEDLE16017101001 JET-NEEDLE1 on diagramx145.151602116021118301 SCREW-THROTTLE STOP16021118301 SCREW-THROTTLE STOP1 on diagramx1118.451603016030100701 VALVE-FLOAT16030100701 VALVE-FLOAT1 on diagramx154.301603116031107701 FLOAT16031107701 FLOAT1 on diagramx158.10160441604400701 CLAMP,FLOAT VALVE1604400701 CLAMP,FLOAT VALVE1 on diagramx13.501612616126138201 VALVE,VACUUM16126138201 VALVE,VACUUM1 on diagramx1216.109200592005129001 FITTING92005129001 FITTING1 on diagramx138.659200992009136501 SCREW,5X1092009136501 SCREW,5X101 on diagramx16.0592009A92009155101 SCREW,DRAIN,6X0.7592009155101 SCREW,DRAIN,6X0.751 on diagramx19.3092009B92009170501 SCREW,4X892009170501 SCREW,4X81 on diagramx13.059203792037153101 CLAMP,TUBE92037153101 CLAMP,TUBE2 on diagramx24.859205592055122201 RING-O,FLOAT CHAMBER92055122201 RING-O,FLOAT CHAMBER1 on diagramx117.409205992059174801 TUBE,3.5X6.5X42092059174801 TUBE,3.5X6.5X4201 on diagramx122.9092059A92059123701 TUBE,6.5X9.5X35092059123701 TUBE,6.5X9.5X3501 on diagramx123.259206392063101401 JET-MAIN,#13592063101401 JET-MAIN,#135 on diagramx13.3592063A92063101501 JET-MAIN,#13892063101501 JET-MAIN,#138 on diagramx13.3592063B92063107401 JET-MAIN,#12892063107401 JET-MAIN,#128 on diagramx13.3592063C92063107501 JET-MAIN,#13092063107501 JET-MAIN,#130 on diagramx13.3592063D92063107601 JET-MAIN,#13292063107601 JET-MAIN,#1321 on diagramx113.359206492064110101 JET-PILOT,#3592064110101 JET-PILOT,#351 on diagramx116.059214492144153801 SPRING,VACUUM VALVE92144153801 SPRING,VACUUM VALVE1 on diagramx122.559217092170149601 CLAMP,TUBE92170149601 CLAMP,TUBE1 on diagramx113.509219092190147301 TUBE,6.5X11.5X16092190147301 TUBE,6.5X11.5X1601 on diagramx17.7092190A92190156001 TUBE,5X8X43092190156001 TUBE,5X8X4301 on diagramx122.15

RefPart NumberDescriptionPart, Description# On Img# Cart$ EachNotes220220AA0408SCREW-PAN-CROS220AA0408SCREW-PAN-CROS4 on diagramx40.40220A220AA0414SCREW-PAN-CROS,4X14220AA0414SCREW-PAN-CROS,4X144 on diagramx43.30223223D0416SCREW-PAN-WS-CROS,4X16223D0416SCREW-PAN-WS-CROS,4X16 on diagramx2.901104411044-1353BRACKET,THROTTLE CABLE11044-1353BRACKET,THROTTLE CABLE1 on diagramx176.001309113091-1259HOLDER,NEEDLE JET13091-1259HOLDER,NEEDLE JET1 on diagramx134.401404116005-1065TOP-CHAMBER,MIXING16005-1065TOP-CHAMBER,MIXING1 on diagramx182.101500115001-1833CARBURETOR-ASSY15001-1833CARBURETOR-ASSY1 on diagramx1698.1015001A15001-1990CARBURETOR-ASSY15001-1990CARBURETOR-ASSY on diagramx876.501600716007-1117SEAT-SPRING,VALVE16007-1117SEAT-SPRING,VALVE1 on diagramx128.701600916009-1803NEEDLE-JET,N1RX16009-1803NEEDLE-JET,N1RX1 on diagramx141.501601416014-1029SCREW-PILOT AIR16014-1029SCREW-PILOT AIR1 on diagramx119.301601616016-1084PLUNGER,STARTER16016-1084PLUNGER,STARTER1 on diagramx151.801601716017-1010JET-NEEDLE16017-1010JET-NEEDLE1 on diagramx155.401602116021-1144SCREW-THROTTLE STOP16021-1144SCREW-THROTTLE STOP1 on diagramx1147.401603016030-1007VALVE-FLOAT16030-1007VALVE-FLOAT1 on diagramx164.101603116031-1056FLOAT16031-1056FLOAT1 on diagramx168.601604416044-007CLAMP,FLOAT VALVE16044-007CLAMP,FLOAT VALVE1 on diagramx14.104302843028-1081DIAPHRAGM,VALVE43028-1081DIAPHRAGM,VALVE1 on diagramx1267.809200992009-1365SCREW,5X1092009-1365SCREW,5X101 on diagramx17.5092009A92009-1551SCREW,DRAIN,6X0.7592009-1551SCREW,DRAIN,6X0.751 on diagramx111.409202292022-1003WASHER,PLAIN92022-1003WASHER,PLAIN1 on diagramx14.4092022A92022-1480WASHER,PLAIN,STOP SPRING92022-1480WASHER,PLAIN,STOP SPRING1 on diagramx15.209203792037-1531CLAMP,TUBE92037-1531CLAMP,TUBE2 on diagramx25.7092037A92037-1886CLAMP92037-1886CLAMP on diagramx9.709204392043-1148PIN,FLOAT92043-1148PIN,FLOAT1 on diagramx18.109205592055-1002RING-O,PILOT ADJUST92055-1002RING-O,PILOT ADJUST1 on diagramx14.4092055A92055-1222RING-O,FLOAT CHAMBER92055-1222RING-O,FLOAT CHAMBER1 on diagramx121.409205992059-1748TUBE,3.5X6.5X42092059-1748TUBE,3.5X6.5X4201 on diagramx127.0092059A92059-1237TUBE,6.5X9.5X35092059-1237TUBE,6.5X9.5X3501 on diagramx127.5092059B92059-1463TUBE,6.5X11.5X15092059-1463TUBE,6.5X11.5X1501 on diagramx135.909206392063-1014JET-MAIN,#13592063-1014JET-MAIN,#135 on diagramx16.4092063A92063-1015JET-MAIN,#13892063-1015JET-MAIN,#138 on diagramx16.4092063B92063-1074JET-MAIN,#12892063-1074JET-MAIN,#128 on diagramx16.4092063C92063-1075JET-MAIN,#13092063-1075JET-MAIN,#130 on diagramx16.4092063D92063-1076JET-MAIN,#13292063-1076JET-MAIN,#1321 on diagramx116.409206492064-1101JET-PILOT,#3592064-1101JET-PILOT,#351 on diagramx119.709208192081-1002SPRING,PILOT ADJUST SCREW92081-1002SPRING,PILOT ADJUST SCREW1 on diagramx15.7092081A92081-1617SPRING,THROTTLE STOP SCRE92081-1617SPRING,THROTTLE STOP SCRE1 on diagramx15.809214492144-1538SPRING,VACUUM VALVE92144-1538SPRING,VACUUM VALVE1 on diagramx126.709217092170-1496CLAMP,TUBE92170-1496CLAMP,TUBE on diagramx16.009219092190-1473TUBE,6.5X11.5X16092190-1473TUBE,6.5X11.5X160 on diagramx9.1092190A92190-1560TUBE,5X8X43092190-1560TUBE,5X8X430 on diagramx26.20

220
220AA0408

Part Diagram Ref: 220

SCREW-PAN-CROS COMMON
EUR 0.14220A
220AA0414

Part Diagram Ref: 220A

SCREW-PAN-CROS COMMON
EUR 1.5511044 110441353

Part Diagram Ref: 11044

BRACKET,THROTTLE CABL KL600-B1
EUR 33.1013091 130911259

Part Diagram Ref: 13091

HOLDER,NEEDLE JET KL250-D2
EUR 15.3813270 132701063

Part Diagram Ref: 13270

PLATE,JOINT STAY VN1500-D1

Arfgitnlst

EUR 15.9114041
160051065

Part Diagram Ref: 14041

TOP-CHAMBER,MIXING ZR1100-A1
EUR 36.9715001 150011830

Part Diagram Ref: 15001

NO LONGER AVAILABLE FROM MANUFACTURER 15001a 150011833

Part Diagram Ref: 15001a

NO LONGER AVAILABLE FROM MANUFACTURER 15001b 150011856

Part Diagram Ref: 15001b

NO LONGER AVAILABLE FROM MANUFACTURER 15001c 150011877

Part Diagram Ref: 15001c

NO LONGER AVAILABLE FROM MANUFACTURER 16007 160071117

Part Diagram Ref: 16007

SEAT-SPRING,THROTTLE ZX900-A1
EUR 12.5716009 160091802

Part Diagram Ref: 16009

NO LONGER AVAILABLE FROM MANUFACTURER 16009a 160091803

Part Diagram Ref: 16009a

NEEDLE-JET KLX250-E1

Gritnlnr

EUR 18.1316014 160141029

Part Diagram Ref: 16014

SCREW-PILOT ADJUST Z250-G2
EUR 9.7516016 160161084

Part Diagram Ref: 16016

PLUNGER,STARTER KLX250-E1
EUR 26.2016017 160171010

Part Diagram Ref: 16017

NEEDLE JET KL250-A2

Gritnlnr

EUR 24.1516017b 160171362

Part Diagram Ref: 16017b

JET-NEEDLE ZR1100-A1

Arfgst

EUR 28.4516021 160211144

Part Diagram Ref: 16021

SCREW-THROTTLE STOP KLE500-A1
EUR 73.1316030 160301007

Part Diagram Ref: 16030

FLOAT VALVE ASSY Z250-A3
EUR 28.1016031 160311056

Part Diagram Ref: 16031

FLOAT KL600-A1
EUR 29.9316044 16044007

Part Diagram Ref: 16044

CLIP, FLOAT VALVE Z750-L1
EUR 2.7543028 430281081

Part Diagram Ref: 43028

DIAPHRAGM,VALVE KLX250-E1

Fggritnlnr

EUR 117.2543028a 430281083

Part Diagram Ref: 43028a

NO LONGER AVAILABLE FROM MANUFACTURER 92005 920051235

Part Diagram Ref: 92005

FITTING KLE500-A3

Arfgitnlst

EUR 6.2392009 920091365

Part Diagram Ref: 92009

SCREW KL250-D2
EUR 3.1792009a 920091551

Part Diagram Ref: 92009a

SCREW,DRAIN ZX1000-B1
EUR 4.8692009b
920091705

Part Diagram Ref: 92009b

SCREW 4X8 VN1500-D1

Arfgitnlst

EUR 1.6292022 920221003

Part Diagram Ref: 92022

WASHER, PLAIN Z750-L1
EUR 1.8392022a 920221480

Part Diagram Ref: 92022a

WASHER,PLAIN,STOP SPR ZX900-A1
EUR 2.2992037 920371531

Part Diagram Ref: 92037

CLAMP,TUBE KL600-A1
EUR 2.5092043
920431148

Part Diagram Ref: 92043

PIN,FLOAT KX250-C1
EUR 3.8492055 920551002

Part Diagram Ref: 92055

""O"" RING,PIROT ADJUST Z750-L1
EUR 1.8092055a 920551222

Part Diagram Ref: 92055a

RING-O,FLOAT CHAMBER KL600-A1
EUR 9.3792055b 920551427

Part Diagram Ref: 92055b

RING-O,4.5X1.5 ZX1000-B1

Fg

EUR 2.2992059
920591748

Part Diagram Ref: 92059

TUBE,3.5X6.5X420 KAF450-B1
EUR 11.8392059a 920591237

Part Diagram Ref: 92059a

TUBE,L=350 KZ750-N1
EUR 12.1192059b 920591463

Part Diagram Ref: 92059b

TUBE,6.5X11.5X150 KL600-A1

Grnr

EUR 16.1592063 920631014

Part Diagram Ref: 92063

MAIN JET,#135 KL250-A2
EUR 7.0892063a 920631015

Part Diagram Ref: 92063a

MAIN JET,#138 KL250-A2
EUR 7.0892063b 920631074

Part Diagram Ref: 92063b

MAIN JET,2ND #128 Z750-L1
EUR 7.0892063c 920631075

Part Diagram Ref: 92063c

MAIN JET,2ND #130 Z750-L1
EUR 7.0892063d 920631076

Part Diagram Ref: 92063d

JET-MAIN,#132 VN1500-D1
EUR 7.0892064 920641101

Part Diagram Ref: 92064

JET-PILOT,#35 ZX900-A1
EUR 8.6692066 920661051

Part Diagram Ref: 92066

PLUG,PILOT AIR SCREW, Z550-G2

Arst

EUR 2.2992081 920811002

Part Diagram Ref: 92081

SPRING,PIROT ADJ SCRW Z750-L1
EUR 2.4692081a 920811617

Part Diagram Ref: 92081a

SPRING,THROTTLE STOP ZX900-A1
EUR 2.5892144 921441538

Part Diagram Ref: 92144

SPRING,VACUUM VALVE ZX600-D1
EUR 11.5992190 921901467

Part Diagram Ref: 92190

TUBE,8X10X15 KAF620-A1

Fg

EUR 1.8792190a 921901473

Part Diagram Ref: 92190a

TUBE 6.5X11.5X160 KLX650-A1

Aritnlst

EUR 3.9192190b 921901560

Part Diagram Ref: 92190b

TUBE,5X8X430 KLX250-D2
EUR 11.48

If you were to browse any KLR250 related forum the most common ailment you'd hear owners complain about is some type of starting or running problem, usually carburetor related. These problems aren't biased to just the KLR, any carbureted bike can experience them. They're usually due to dirt in the fuel clogging a jet, or varish gumming everything up. The only solution is to remove the carb from the bike and give it a thorough cleaning and inspection. Thats what this article is meant to do, show you the basics of the KLR250 carburetor and give a quick run through on how to clean it.We won't get into how a carb works, but if you're interested in learning more check out The Care and Feeding of the Keihn Carb.

The KLR 250 comes with a Keihn CVK34 carburetor. Don't let the parts diagram to the left fool you, CVK34 is a very simple design. To clean the carb you'll need to remove it from the bike. Probably one of the more painful processes whenever you have to work on your bike's carb is trying to get it out of the bike. At the very least it'll require removing the side plastics, seat, and fuel tank, though we have found that unbolting the exhaust muffler and the top bolts of the subframe (the part the seat bolts to) make things easier by allowing you to pivot the entire subframe backwards giving better access to the carb. Once you've gotten to the carb follow these steps to disconnect and remove it.

Removal:
1. Turn off the fuel petcock on the fuel tank
2. Place a container under the fuel drain hose. That is the hose which leads from the fuel drain screw to just in front of the rear wheel.
3. Open drain screw, located on the bottom right side of the carb (on the float bowl) and allow all of the fuel to drain from the carb.
4. Remove the fuel line from the left side of the carb (black rubber line from the fuel tank)
5. Remove the throttle cables, one screw holds the bracket in place.
6. Carefully unscrew the plastic choke cable nut from the left side of the carburetor. This is where the choke cable screws into the carb. The plastic nut is very fragile so be careful!
7. Loosen the clamp on the front side of the carb holding it to the engine.
8. Remove the rear carb to airbox tube

OK now you should have the carb out of the bike and holding it in your hands. Next step is tearing it down while being very careful not to lose or damage anything in the process.

Teardown:
1. Remove the four screws on the plastic piece on the top of the carb. Underneath there should be a diaphragm, spring, slide, needle and white piece of plastic. Make a mental note of the order of those parts (slide, needle, white plastic piece, spring) and remove them. Be careful not to tear the rubber diaphragm.
2. Remove the float bowl. That is the metal bowl on the bottom of the carb, held in place with four screws. Be careful when removing it as the float and needle valve can fall out. Make a note of the position of the float and needle and remove them.
3. Next step is to unscrew the main and pilot jets from the carb body. (see diagram above for their location)

Pilot Screw Info:
The KLR's carb has a pilot mixture screw which controls the amount of fuel that enters the engine while at idle. However to stop owners from fiddling with it Kawasaki covered the screw with a small tin cap. The only way to get to this screw is to carefully drill a small hole in the tin cap and then pry it off with a small screw driver. The utmost care must be taken so you don't screw all of the way through to the pilot screw itself. Once the screw is accessible then you can remove it. There should be an o-ring, washer, and spring on the end of it, note their order and set them to the side.

Cleaning:
Thats about all you need to disassemble. Wasn't that hard was it? Now its time to clean everything. Just about everyone has their own way of doing this but what we suggest is buying a few bottles of carb cleaner (the kind you pour in your car's fuel tank) and a couple cans of spray type carb cleaner that have the small plastic tubes on them. Fill a small container with the carb cleaner (bottle type) and soak all of the metal parts in it, including the carburetor body. Note: Do not use either carb cleaner on any plastic or rubber parts, it'll eat them. What you're trying to accomplish is the removal of all varnish from inside the carb body, and jets. After they've soaked for a couple of hours its time to spray out all of the small passages in the carb body, and the tiny holes in jets with the spray type carb cleaner and then follow it up with a blast of compressed air. You're trying to make sure there is nothing clogging up those small holes, you leave one grain of sand behind and you'll be doing this again so be diligent! By this point you should have a sparkling clean carburetor, all that is left to do is reassemble everything.

Reassembly:
There isn't much to say here, just reassemble everything in the reverse order you took it apart. When the time comes to re-install the pilot screw make sure the o-ring, washer, and spring are in place and screw it in all of the way and back out two full turns. (further adjustment may be needed but this is a good starting point) When you re-install the slide components be careful not to pinch or tear the rubber diaphragm.

Float Adjustment:
While you have the carb apart and cleaned this is the perfect time to check the float height adjustment. Simply install the float and needle valve onto the carb body and hold it as shown in the diagram to the left. You want the needle to be lying on its seat but not pushed down. To check for proper adjustment measure from the float bowl mating surface, and the top of the float. (4) The adjustment should be 17mm. If you find its not 17mm then you correct it by ever so slightly bending the float bowl tang with a pair of needle nose pliers. (see arrow in this picture) Small adjustment result in big changes in the float height, so go easy. Once you've got it to 17mm you're all set.

Thats it! Now re-install the carb back in the bike and you're good to go!

Image Sources: Gadjetjq.com- KLR650.net- Kawasaki.com
Note: The top image is of a CVK40. While it is a different carburetor than the CVK34 in the KLR 250 their layouts are almost identical.