How to Clean & Rebuild a Kawasaki KLX Carburetor

A clean carburetor can make the difference between your dirt bike running like a champ, or like a chump.

In fact, if the carb gets dirty and clogged enough, it'll prevent your bike from running at all. Follow the step-by-step guide below and watch our Kawasaki KLX110 carburetor cleaning video above to disassemble, clean and rebuild the carburetor on your Kawasaki dirt bike.

Tools and Parts Needed - Kawasaki KLX Carburetor Cleaning

Tools

  • Ratchet
  • 8mm socket
  • 8mm wrench

 

  • Screwdrivers
  • Pliers

Parts

The exact parts you'll need depends upon how dirty or worn your bike's carburetor is. You can find all the individual OEM Kawasaki parts for a KLX110 carburetor, as well as a complete carburetor assembly here.

Kawasaki KLX 110 carburetor cleaning

Removing a Kawasaki KLX110 Carburetor

Step 1. Shut off the fuel at the fuel tap.

Step 2. Remove the drain screw, and drain any remaining fuel from the float bowl. Reinstall the drain screw.

Kawasaki KLX carburetor removal

Step 3. Remove the two 8mm mounting bolts from the rear of the carburetor body.

Step 4. Release the clamp, and remove the fuel line from the right side of the carburetor.

Step 5. Remove the spacer from between the carburetor and the intake pipe.

Kawasaki KLX carburetor assembly

NOTE: The O-ring in the spacer faces the intake pipe so you can reinstall it later facing in the same direction.

Step 6. Loosen the clamp, and remove the duct on the front of the carburetor that leads to the airbox.

Kawasaki KLX dirt bike carb assembly

Step 7. Release the clamp, and remove the breather line from the left side of the carburetor.

Step 8. Unscrew the cap from the top of the carburetor, and remove the throttle spring and needle jet from the carburetor body.

Kawasaki KLX110 carburetor removal

Step 9. Disconnect the choke cable from the carburetor body, and remove the carburetor from the motorcycle.

Kawasaki KLX dirt bike carb removal

PRO TIP: If the fuel in the tank is old and stale, now is a good time to drain it. Put a container under the fuel line, and turn the fuel tap to reserve.

Disassembling a Kawasaki KLX110 Carburetor

PRO TIP: Clean the outside of the carburetor assembly with contact/brake cleaner to remove as much dirt and debris as possible. Less debris means less chance of any contaminants getting into the carburetor when you disassemble it.

Step 1. Remove the two float bowl screws and the float bowl from the carburetor body.

Kawasaki KLX 110 carb disassembly

Step 2. Pull the retaining pin from the top of the float, and remove the float from the float bowl.

Step 3. Inspect the float valve for cracks or damage at its rubber tip, and replace the valve if necessary.

Kawasaki KLX dirt bike carb parts diagram

Step 4. Remove the main and needle jet assembly, and take the idle jet off from the carburetor body.

Cleaning a Kawasaki KLX110 Carburetor

Step 1. Clean the jets with carb cleaner, making sure there are no traces of dirt or debris left on or in the jets. 

NOTE: If any of the jets are worn or the buildup of contaminants is such that they can't be adequately cleaned, replace the jets. Even the smallest contaminants can clog a carburetor jet, so be very thorough when cleaning them.

Kawasaki KLX carburetor jet cleaning

Step 2. Flush the channels in the carburetor body that hold the main and idle jets with carb cleaner to remove all traces of dirt or debris.

Step 3. Clean the inside of the float bowl with carb cleaner to remove any dirt or debris. 

PRO TIP: Avoid getting carb cleaner on the float bowl's gasket, because carb cleaner will cause the gasket to swell up and make reassembling the float bowl and carburetor body difficult. 

Rebuilding a Kawasaki KLX110 Carburetor

Step 1. Reinstall the main and needle jet assembly, followed by the idle jet into the carburetor body.

Kawasaki KLX 110 carb jets installation

NOTE: Don't overtighten the jets, because they're made of brass and it's easy to damage them.

Step 2. Set the float valve back in place on the float, then reinstall the float back into the carburetor body, and the retaining pin to secure the float in place.

Kawasaki dirt bike carburetor rebuild

Step 3. Reinstall the float bowl and you're done rebuilding the carburetor.

To reinstall the carburetor, simply reverse the steps you followed to remove it from the motorcycle.

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