Hi all, I have had continuous trouble with cold starts since purchasing this bike 3 years ago ('95 KLR 250 w/only 4k on the clock).
I've been "cheating" by using starting fluid (I'm embarrassed to admit that yes...I drilled a small hole in the air cleaner box, installed a small "door" to cover it after shooting ether into the box). After all, I'm in my 40's, have flamingo legs and it's killer to kick this animal 50+ times before bringing her to life.
Attempting to take one last stab at her before just buying another carb, I've finally identified the trouble.
Seems that the starter jet is / has been clogged.
Looks like the P.O. found out too as there are witness marks on the brass flange of the starter jet (assuming left by vice grips or pliers) and also it appears that he started to drill it out as there is material lapped over the hole...and she's plumb plugged beyond that...
replaced Pilot and main jets, idler screw, etc, float plunger
Installed a brand new plunger assembly ("choke")
Cleaned carb 4x now
Opened up the air box to ensure good air flow
replaced air filter
I'm CERTAIN this is my problem. Fuel can't make it's way through the winding passages up to the choke circuit for the "next" start.
Wondering if anyone has experienced similar trouble and what the thoughts might be if I were to just drill out the STARTER jet.
Here's a pic of my situation (man, that's a tough picture to get).
And also a pic from KLR250/blogspot.
Any help / advice would be GREATLY appreciated!