2007 issues - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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  • 4 Post By DPelletier
  • 1 Post By pdwestman
 
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post #1 of 8 Old 02-22-2016, 11:30 AM Thread Starter
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Join Date: Jan 2016
Location: Middle Tennessee
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2007 issues

Hi ya'll, I recently bought a 2007 with 21,000 miles on it for $1000 and as you would expect, it has a few issues. It needs a new battery (started with a charger on it) the front brake is not working, the choke lever is broken off its mount, the steering head bearings are loose (and/or worn) and the petcock leaks if left on while the bike isn't running. I have two questions, one, I have read about these things having a vacuum-operated petcock, is this a symptom that it needs to rebuilt? And if so, is there a "rebuild kit"?
My second question is more general, are there any other well-known things that I should look for in a 2007 at this mileage?

I began racing motocross at 15, in 1975 and have only owned dirt bikes. This is my first time owning a motorcycle with a license plate and it already seems much more complex. Combine that with the fact that my health is not so good (Chronic Fatigue Syndrome) and I am considering just taking it to a shop to be gone over. Not having a lot of money, as well as pride make me not want to resort to that. Any suggestions are welcome.

Last edited by freds4; 02-22-2016 at 01:10 PM.
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post #2 of 8 Old 02-22-2016, 11:36 AM
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Yes, you should address the "doohickey" and check the valves in addition to the other items you mention. Proper parts are available from Eaglemike.com

....as far as the petcock goes (and especially since you have experience with bikes with manual petcocks) my preferred solution is to replace the stock vacuum petcock with a Yamaha Raptor manual unit....also available from Eaglemike. You can also rebuild the stock one or there is a kit to convert it to manual.

Oh, speaking of Eaglemike, he also has a billet aluminum choke relocation bracket which works well and positions the lever out of harms way.

2 cents,
Dave
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post #3 of 8 Old 02-22-2016, 08:46 PM
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Quote:
Originally Posted by freds4 View Post
. . . and the petcock leaks if left on while the bike isn't running.
Intriguing statement!

How do you know the petcock leaks?

Even if the petcock leaked, a functioning float valve in the carburetor would stop any fuel flow when the float bowl filled, all opaque to an observer.

Where, exactly, do you observe fuel leaking? For example, around petcock gasket? Around fuel lines? Out carb float bowl overflow? (If this last one, float valve is not sealing; petcock may be leaking also.)

Last edited by Damocles; 02-22-2016 at 08:49 PM.
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post #4 of 8 Old 02-22-2016, 08:54 PM
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Quote:
Originally Posted by Damocles View Post
Intriguing statement!

How do you know the petcock leaks?

Even if the petcock leaked, a functioning float valve in the carburetor would stop any fuel flow when the float bowl filled, all opaque to an observer.

Where, exactly, do you observe fuel leaking? For example, around petcock gasket? Around fuel lines? Out carb float bowl overflow? (If this last one, float valve is not sealing; petcock may be leaking also.)
My bet is around the fuel tap handle 'O'-ring, Damocles. External leakage.

Fuel can not leak out of the 'float bowl overflow', because there is NO overflow stand pipe. (It is a 'drain screw' only nipple.) It is an EPA controlled issue. They would rather 'fill the crankcase' with raw gas, than spill a pint on 'Gods Green Earth'. That doesn't stop the fuel tap handle from leaking thou!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting

Last edited by pdwestman; 02-22-2016 at 09:03 PM. Reason: Added text
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post #5 of 8 Old 02-22-2016, 09:01 PM
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Quote:
Originally Posted by pdwestman View Post
My bet is around the handle 'O'-ring, Damocles. External leakage.
Good bet! If so, some petcock maintenance or replacement seems in order.

I think the petcock parts are fiched and available. Petcock could still shut off fuel to carb, with such an external leak, seems like.
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post #6 of 8 Old 02-22-2016, 09:05 PM Thread Starter
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Join Date: Jan 2016
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Quote:
Originally Posted by Damocles View Post
Intriguing statement!

How do you know the petcock leaks?

Even if the petcock leaked, a functioning float valve in the carburetor would stop any fuel flow when the float bowl filled, all opaque to an observer.

Where, exactly, do you observe fuel leaking? For example, around petcock gasket? Around fuel lines? Out carb float bowl overflow? (If this last one, float valve is not sealing; petcock may be leaking also.)

Fuel is leaking from the petcock itself, only when in the "on" position, only with the engine not running. Weird, I know. I have already decided to simply replace the petcock with a regular manual one.
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post #7 of 8 Old 02-22-2016, 09:14 PM
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Quote:
Originally Posted by freds4 View Post
Fuel is leaking from the petcock itself, only when in the "on" position, only with the engine not running. Weird, I know. I have already decided to simply replace the petcock with a regular manual one.
freds4,
$3.60 for a handle 'o'-ring, $4.18 for a selector gasket.
I DO like the 'automatic' OFF of the vacuum valve. I have never had gas in my 1987 crankcase!
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #8 of 8 Old 02-22-2016, 10:17 PM
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Quote:
Originally Posted by pdwestman View Post
My bet is around the fuel tap handle 'O'-ring, Damocles. External leakage.

Fuel can not leak out of the 'float bowl overflow', because there is NO overflow stand pipe. (It is a 'drain screw' only nipple.) It is an EPA controlled issue. They would rather 'fill the crankcase' with raw gas, than spill a pint on 'Gods Green Earth'. That doesn't stop the fuel tap handle from leaking thou!
Thanks for the correction/clarification, Paul!

Somewhere, in the dark recesses of my flawed memory, I recalled fuel flowing from the float bowl drain of a Kawasaki conveyance of some sort, as a result of an ineffective float valve seal. Might have been a CVK32, on an ATV; might have been only in my IMAGINATION!

Regardless, I stand CORRECTED! And, I'm sincerely grateful for the correction.
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