Wilsons Sandbox

The midrange power and torque is definitely stronger. However it comes at a price. Originally getting 400klm to a tank. Went down to 250. Changed needle clip position then up to 300. It is still running rich so I need to keep fiddling which is actually my point. It takes time to get it right. No standard setting that gets posted out there actually works perfectly. In summary, I would not go back to standard. I want the extra power to carry my weight (230lb - 110kg) and I enjoy the way it now winds up between 2500 and 5000 and boogies. Overtaking cars on the highway is a safer proposition too. Note that this mod does not turn this bike into a crazy KTM 525 for example. With respect to fuel consumption, I carry an extra 5 litre or 10 litres in my luggage if I have too. The standard KLR is still a very good bike by the way. Be prepared to get a little frustrated doing this. You will get good at pulling the bike apart to access the carby at least. I trust this helps you make a decision. Greg B OZ

--- On Fri, 8/8/08, rainbowwarrior24us wrote: From: rainbowwarrior24us Subject: [DSN_KLR650] carb and air box mods To: DSN_KLR650@yahoogroups.com Received: Friday, 8 August, 2008, 4:53 AM I am wondering if anyone made the modifacations to the carb and air box I saw in MARKNET ? if so how much of a power increase and what kind of mpg changes ? ty Win a MacBook Air or iPod touch with Yahoo!7. http://au.docs.yahoo.com/homepageset [Non-text portions of this message have been removed]

Hi Ty, I didn't see if anyone responded to your post about the intake mods, so I can at least tell you about my experience with doing the carb mods, I haven't done the airbox mods. I think the carb mods I did followed what I saw on a link to a KLR650.net post which was also pretty close to I believe the info provided by DynoJet maybe on their site. I drilled the slide, installed one #4 brass washer under the needle and opened up the mixture screw to1.75 turns. I presently also have the stock filter installed. As far as how this part of the mods work there seems to be a bit more power measured by the seat of the pants, throttle response is quicker, Although I found it initially a little abrupt at low speed in 1st gear ( stock gearing) offroad if I was picking my way through a rocky spot for example. The popping that used to happen when rolling off the throttle is gone, from the factory my mixture screw was out less the a turn from bottomed. And as far as gas useage goes the last tank has about 400km of my normal mixture of backroads at 100-110 kph and gravel and mud roads at varied speds which i believe required 16.8 litres which although I never checked the mileage is about what was the norm before the mods. All in all from the mods I did the gains were small but noticeable but the losses seem to be pretty much zero so I would say they were worth doing. Hope this helps and have a great weekend.....Greg

--- On Thu, 8/7/08, rainbowwarrior24us wrote: From: rainbowwarrior24us Subject: [DSN_KLR650] carb and air box mods To: DSN_KLR650@yahoogroups.com Received: Thursday, August 7, 2008, 3:53 PM I am wondering if anyone made the modifacations to the carb and air box I saw in MARKNET ? if so how much of a power increase and what kind of mpg changes ? ty __________________________________________________________________ Yahoo! Canada Toolbar: Search from anywhere on the web, and bookmark your favourite sites. Download it now at http://ca.toolbar.yahoo.com [Non-text portions of this message have been removed]

Ty I didn't reply to your original post because I've never looked at Marknet. However I have re-jetted my 2002 KLR with excellent results. I did this for performance not fuel mileage. If I wanted fuel mileage I'd get a scooter not a KLR. My KLR650 is a 2002 model. I've made many modifications to it to improve reliability and performance. Below are the induction modifications that have worked well for me. I purchased individual parts to re-jet the carburetor rather than buy a jet kit. There was a little trial and error with some of the parts but listed below is the final setup that works great. Doug in NC ---------- I tried a few different settings and finally settled on the settings listed below. I had a 152 main jet in for a while but found it a little too rich. It may work better at lower elevations though. I've also tried a 42 pilot jet. Harley Davidson p/n 27171-8 but went back to the stock 40 pilot. I ridden the bike for a few years with these final settings and am very happy with it. I removed the backfire screen prior to the re-jetting and didn't notice any significant changes but it has to flow more air without that screen. Hope some of this helps you. My fuel mileage did drop from a little under 50 mpg to a little over 40 mpg. That's US gallons. You could likely get better fuel economy if you rode it easy but I run the KLR pretty hard and have fun doing it. I'm a retired Enduro champion so know how to ride off road. Most of my riding is done between 2,000 ft and 5,000 feet elevation here in the North Carolina mountains. On one trip to Florida for Bike Week (sea level) I noticed the bike pinged a little when it got hot and I lugged it. I just put in a tank of premium gas and it ran OK. I never have that problem at home. I have ridden the 08 KLR that belongs to a friend of mine that asked me to do some modifications to it to make it perform better and be more reliable. With stock jetting it's a dog. After installing a Dyno-Jet kit it ran much better and he was happy with it but my seat of the pants dyno tells me my re-jetted 2002 ran much better than the Dyno-Jetted 08 model. ---------- Carburetor Jetting Item: Stock: Modified to: Main Jet 148 150 Pilot Jet 40 tried 42 then back to 40 Jet Needle N31R N1-TB for KLX-R p/n 16009-1794 also used KLX needle clip #92037-1401 and KLX needle spacer #92143-1667 Jet Needle Clip 4th notch from top Pilot Screw 1 3/8 turns 2 turns Enlarged slide vacuum hole to .125" by drilling with a 1/8" drill. Removed backfire screen from inside of air box Cut the top of the airbox opening in an L shape to allow more air flow Installed K&N air filter Exhaust is stock ---------- At 09:18 AM 8/9/2008, you wrote:

>Re: carb and air box mods > Posted by: "Greg May" gmay131313@... gmay131313 > Date: Fri Aug 8, 2008 2:30 pm ((PDT)) > > > Hi Ty, I didn't see if anyone responded to your post about the > intake mods, so I can at least tell you about my experience with > doing the carb mods, I haven't done the airbox mods. I think the > carb mods I did followed what I saw on a link to a KLR650.net post > which was also pretty close to I believe the info provided by > DynoJet maybe on their site. I drilled the slide, installed one #4 > brass washer under the needle and opened up the mixture screw > to1.75 turns. I presently also have the stock filter installed. > As far as how this part of the mods work there seems to be a bit > more power measured by the seat of the pants, throttle response is > quicker, Although I found it initially a little abrupt at low speed > in 1st gear ( stock gearing) offroad if I was picking my way > through a rocky spot for example. The popping that used to happen > when rolling off the throttle is gone, from the factory my mixture > screw was out less the a turn from bottomed. And as far as gas > useage goes the last tank has about 400km of my normal mixture of > backroads at 100-110 kph and gravel and mud roads at varied speds > which i believe required 16.8 litres which although I never checked > the mileage is about what was the norm before the mods. > All in all from the mods I did the gains were small but > noticeable but the losses seem to be pretty much zero so I would > say they were worth doing. Hope this helps and have a great weekend.....Greg > > >--- On Thu, 8/7/08, rainbowwarrior24us wrote: > >From: rainbowwarrior24us >Subject: [DSN_KLR650] carb and air box mods >To: DSN_KLR650@yahoogroups.com >Received: Thursday, August 7, 2008, 3:53 PM > > > > > > >I am wondering if anyone made the modifacations to the carb and air box >I saw in MARKNET ? if so how much of a power increase and what kind >of mpg changes ? ty

---------- Doug Pippin 828-684-8488 d_pippin_89@... ---------- [Non-text portions of this message have been removed]

Guys We have just returned from across Canada trip 12785 Kilos in total One red 2008 one blue 2008 Carb mod done on the red one but not the air box. The blue one (me) had a bigger rider and heaver luggage Bone stock At slow speed the blue one was significantly better on Gas approx. 10 MPG (imperial) we checked every time. At speeds over 100 Kilos (62 MPH) It was(the red one) better on gas than the blue one by approx. 1 liter per tank about 400 Kilos Top speed approx. both the same I had a GPS on mine 140 Kph fully loaded . i weigh about 200LBS I had a Rev pack and two 1550 Pelican cases with about 100lbs of gear in them.. We tried this several times. We lined the bikes up in fifth gear at about 3000rpm (We have communicators ) Then said go . The blue one was consistently quicker accelerating. (The heaver loaded one.) #1So from that we are to establish the blue ones are always faster #2 the 22 cent mod does not work on the red ones #3 the 22 cent mod does not work without the air box mod. #4 the data we get about about KLRs are not all the same. #5 KLRs are not all the same #6 the guy who wrote this rides a blue bike. #7We all have fun on KLRs ----- Original Message ---- From: Greg May To: DSN_KLR650@yahoogroups.com; rainbowwarrior24us Sent: Friday, August 8, 2008 5:30:20 PM Subject: Re: [DSN_KLR650] carb and air box mods Hi Ty, I didn't see if anyone responded to your post about the intake mods, so I can at least tell you about my experience with doing the carb mods, I haven't done the airbox mods. I think the carb mods I did followed what I saw on a link to a KLR650.net post which was also pretty close to I believe the info provided by DynoJet maybe on their site. I drilled the slide, installed one #4 brass washer under the needle and opened up the mixture screw to1.75 turns. I presently also have the stock filter installed. As far as how this part of the mods work there seems to be a bit more power measured by the seat of the pants, throttle response is quicker, Although I found it initially a little abrupt at low speed in 1st gear ( stock gearing) offroad if I was picking my way through a rocky spot for example. The popping that used to happen when rolling off the throttle is gone, from the factory my mixture screw was out less the a turn from bottomed. And as far as gas useage goes the last tank has about 400km of my normal mixture of backroads at 100-110 kph and gravel and mud roads at varied speds which i believe required 16.8 litres which although I never checked the mileage is about what was the norm before the mods. All in all from the mods I did the gains were small but noticeable but the losses seem to be pretty much zero so I would say they were worth doing. Hope this helps and have a great weekend..... Greg

--- On Thu, 8/7/08, rainbowwarrior24us wrote: From: rainbowwarrior24us Subject: [DSN_KLR650] carb and air box mods To: DSN_KLR650@yahoogro ups.com Received: Thursday, August 7, 2008, 3:53 PM I am wondering if anyone made the modifacations to the carb and air box I saw in MARKNET ? if so how much of a power increase and what kind of mpg changes ? ty ____________ _________ _________ _________ _________ _________ _ Yahoo! Canada Toolbar: Search from anywhere on the web, and bookmark your favourite sites. Download it now at http://ca.toolbar yahoo.com. [Non-text portions of this message have been removed] __________________________________________________________________ Yahoo! Canada Toolbar: Search from anywhere on the web, and bookmark your favourite sites. Download it now at http://ca.toolbar.yahoo.com [Non-text portions of this message have been removed]

Hi Paul, I have an 08 and did the carb mods. I took the carb off and checked the float level first and it was good. I tried several shims under the needle from .o2o-.030 and also tried the idle mixture screw from 1 1/2 - 2 turns out. Stock air filter and airbox. Although the bike ran stronger in some areas, overall, it ran better stock. So it is back where it started with no shim and the pilot screw 1 5/8 turns out. I think you are right that different bikes react differently to these mods. I read where guys get good performance with the pilot 2 turns out. My bike runs like crap at that setting. Larry. --- In DSN_KLR650@yahoogroups.com, Paul Statham wrote:

> > Guys > We have just returned from across Canada trip 12785 Kilos in total > One red 2008 one blue 2008 > Carb mod done on the red one but not the air box. > The blue one (me) had a bigger rider and heaver luggage Bone stock > At slow speed the blue one was significantly better on Gas approx.

10 MPG (imperial) we checked every time.

> At speeds over 100 Kilos (62 MPH) It was(the red one) better on gas

than the blue one by approx. 1 liter per tank about 400 Kilos

> Top speed approx. both the same > I had a GPS on mine 140 Kph fully loaded . i weigh about 200LBS I

had a Rev pack and two 1550 Pelican cases with about 100lbs of gear in them..

> We tried this several times. > We lined the bikes up in fifth gear at about 3000rpm (We have

communicators ) Then said go .

> The blue one was consistently quicker accelerating. (The heaver

loaded one.)

> #1So from that we are to establish the blue ones are always faster > #2 the 22 cent mod does not work on the red ones > #3 the 22 cent mod does not work without the air box mod. > #4 the data we get about about KLRs are not all the same. > #5 KLRs are not all the same > #6 the guy who wrote this rides a blue bike. > #7We all have fun on KLRs > > > > > > > > ----- Original Message ---- > From: Greg May > To: DSN_KLR650@yahoogroups.com; rainbowwarrior24us

> Sent: Friday, August 8, 2008 5:30:20 PM > Subject: Re: [DSN_KLR650] carb and air box mods > > > > Hi Ty, I didn't see if anyone responded to your post about the

intake mods, so I can at least tell you about my experience with doing the carb mods, I haven't done the airbox mods. I think the carb mods I did followed what I saw on a link to a KLR650.net post which was also pretty close to I believe the info provided by DynoJet maybe on their site. I drilled the slide, installed one #4 brass washer under the needle and opened up the mixture screw to1.75 turns. I presently also have the stock filter installed.

> As far as how this part of the mods work there seems to be a bit

more power measured by the seat of the pants, throttle response is quicker, Although I found it initially a little abrupt at low speed in 1st gear ( stock gearing) offroad if I was picking my way through a rocky spot for example. The popping that used to happen when rolling off the throttle is gone, from the factory my mixture screw was out less the a turn from bottomed. And as far as gas useage goes the last tank has about 400km of my normal mixture of backroads at 100-110 kph and gravel and mud roads at varied speds which i believe required 16.8 litres which although I never checked the mileage is about what was the norm before the mods.

> All in all from the mods I did the gains were small but

noticeable but the losses seem to be pretty much zero so I would say they were worth doing. Hope this helps and have a great weekend..... Greg

> > > --- On Thu, 8/7/08, rainbowwarrior24us

yahoo.com> wrote:

> > From: rainbowwarrior24us > Subject: [DSN_KLR650] carb and air box mods > To: DSN_KLR650@yahoogro ups.com > Received: Thursday, August 7, 2008, 3:53 PM > > I am wondering if anyone made the modifacations to the carb and air

box

> I saw in MARKNET ? if so how much of a power increase and what kind > of mpg changes ? ty > > ____________ _________ _________ _________ _________ _________ _ > Yahoo! Canada Toolbar: Search from anywhere on the web, and

bookmark your favourite sites. Download it now at

> http://ca.toolbar yahoo.com. > > [Non-text portions of this message have been removed] > > > > >

__________________________________________________________________

> Yahoo! Canada Toolbar: Search from anywhere on the web, and

bookmark your favourite sites. Download it now at

> http://ca.toolbar.yahoo.com > > [Non-text portions of this message have been removed] >

--- In DSN_KLR650@yahoogroups.com, Paul Statham wrote:

> > Guys > We have just returned from across Canada trip 12785 Kilos in total >

Paul, If you carried 12784 Kilos in Canada, and got away with it, I suggest you retire...and I am NOT going to ask what was in those kilos. I don't chase those that dealt in Kilos, no more. However, if your RIDE was 12785 KM, welcome home. I am sure you had fun! revmaaatin. who can tell the difference from an apple from an orange, and a Kilo from a kilometer.

Hello Rev.... You been listening to too many Arlo Guthrie songs.... albatross walking on a moving floor, trippin on the escalator

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote: > > --- In DSN_KLR650@yahoogroups.com, Paul Statham > wrote: > > > > Guys > > We have just returned from across Canada trip 12785 Kilos in total > > > > Paul, > If you carried 12784 Kilos in Canada, and got away with it, I suggest > you retire...and I am NOT going to ask what was in those kilos. I > don't chase those that dealt in Kilos, no more. > > However, if your RIDE was 12785 KM, welcome home. I am sure you had > fun! > > revmaaatin. who can tell the difference from an apple from an orange, > and a Kilo from a kilometer. >

--- In DSN_KLR650@yahoogroups.com, "albatrossklr" wrote:

> > Hello Rev.... > > You been listening to too many Arlo Guthrie songs.... > > albatross > walking on a moving floor, trippin on the escalator

Albatross, No, Not Arlo Gutrie. Just reading the post as written. revmaaatin. who once tried to read someone's mind--and found it hard to read a blank page

> > --- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote: > > > > --- In DSN_KLR650@yahoogroups.com, Paul Statham > > wrote: > > > > > > Guys > > > We have just returned from across Canada trip 12785 Kilos in

total

> > > > > > > Paul, > > If you carried 12784 Kilos in Canada, and got away with it, I

suggest

> > you retire...and I am NOT going to ask what was in those kilos.

I

> > don't chase those that dealt in Kilos, no more. > > > > However, if your RIDE was 12785 KM, welcome home. I am sure you

had

> > fun! > > > > revmaaatin. who can tell the difference from an apple from an

orange,

> > and a Kilo from a kilometer. > > >

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote:

> > --- In DSN_KLR650@yahoogroups.com, "albatrossklr" > wrote: > > > > Hello Rev.... > > > > You been listening to too many Arlo Guthrie songs.... > > > > albatross > > walking on a moving floor, trippin on the escalator > > Albatross, > > No, Not Arlo Gutrie. Just reading the post as written. > > revmaaatin. who once tried to read someone's mind--and found it hard > to read a blank page > >

So Rev, How many Kilos of that "Native American Herbal Toothache Remedy" have you collected; and are you SURE it doesn't affect your ability to read? "I had my head examined, and they didn't find anything." - Mom