fuel always drips from the airbox drain... - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 2Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 47 Old 06-09-2016, 10:21 PM Thread Starter
1st Gear
 
Join Date: Jun 2016
Posts: 21
fuel always drips from the airbox drain...

and comes from the carb overflow while running. to be clear, fuel comes out of the airbox even while shut off and if you tip the bike fuel come out of the ab.much faster. is this just a float valve issue or some thing much more sever? thanks, just got this bike yesterday. year2000 not a california model.ride on
phihallklr650 is offline  
Sponsored Links
Advertisement
 
post #2 of 47 Old 06-09-2016, 11:33 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,604
Your carb needs to be removed, disassembled and thoroughly cleaned. Then the "brass float valve seat" needs to be polished with metal polish! You will probably have to make your own "Q"-tip the old fashioned way!

There is NO overflow 'stand-pipe' in the float bowl like a toilet tank or dirt bike carb to deal with this kind of flooding on a KLR!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #3 of 47 Old 06-09-2016, 11:56 PM Thread Starter
1st Gear
 
Join Date: Jun 2016
Posts: 21
thank you, very helpful. i should also add that fuel comes from the airbox even when the petcock is off. it seems like a lot of fuel and itnever seems to stop. tilt the bike a bunch runs out. come back later and it still runs out. shouldnt the ab dry out and wih the petcock off shouldnt the fuel not come out any more. im quit confused. thanks so much.
phihallklr650 is offline  
 
post #4 of 47 Old 06-10-2016, 11:18 AM
4th Gear
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,387
So am I; there is no way for fuel to get from the tank to the carb with the petcock off....at least not if it's working properly. The petcock is obviously pooched as is the float valve.

If it was mine, I'd clean the carb and probably just replace the float valve.....then I'd toss the vacuum petcock in the garbage and install a Yamaha Raptor bolt in manual replacment....available from Eagle Mfg & Eng. I'd probably do a KLX jet kit (also from EM) while I was in there.

Check your oil to make sure you haven't been getting fuel in your crankcase (oil will be overfilled and smell of gas) If it has, drain the oil an refill; fuel contaminated oil is not good for your engine.

Dave
DPelletier is offline  
post #5 of 47 Old 06-10-2016, 11:19 AM
4th Gear
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,387
...and clean out your airbox, clean your filter and re-oil too; the gas has probably disolved your filter oil.

Dave
DPelletier is offline  
post #6 of 47 Old 06-10-2016, 01:42 PM Thread Starter
1st Gear
 
Join Date: Jun 2016
Posts: 21
i pulled the carb and tested the petcock for leaks. it did drip for a while but has stopped...? there is fuel in the oil as well...?

Sent from my SPH-D710 using Tapatalk
phihallklr650 is offline  
post #7 of 47 Old 06-10-2016, 10:07 PM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,261
Quote:
Originally Posted by phihallklr650 View Post
............ there is fuel in the oil as well...? ........
Is that a question or a statement? If the oil level is higher than normal or if you smell gas at the oil filler hole, I would change the oil.

One new owner was confused on which way to turn the petcock for "OFF" and was actually turning it to "RES".
GoMotor is offline  
post #8 of 47 Old 06-10-2016, 10:35 PM Thread Starter
1st Gear
 
Join Date: Jun 2016
Posts: 21
hi thanks. they were both statements. and wondering why. the petcock actually seems to leek more in the off position than on. however its only enough to wet your finger.

Sent from my SPH-D710 using Tapatalk
phihallklr650 is offline  
post #9 of 47 Old 06-10-2016, 10:43 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,604
Quote:
Originally Posted by phihallklr650 View Post
i pulled the carb and tested the petcock for leaks. it did drip for a while but has stopped...? there is fuel in the oil as well...?

Sent from my SPH-D710 using Tapatalk
phihallklr650,
Yes there is probably fuel in your engine oil. Because there is No overflow drain stand pipe in the KLR carb like there is in your toilet!

Unlike DPelletier, I personally like the standard Vacuum operated fuel valve of the KLR. Why? Because most owners are too LAZY to take 2 seconds to turn a manual valve OFF! Like they should.

Repair of the vacuum fuel valve usually consists of 1, 92055-1111 'o'-ring and 1, 43049-1017 selector gasket. (Kaw. calls it a packing gland.) Less than $10.00 USD for both pieces.
Occasionally one needs a 43028-1033 diaphragm, about $17.00 USD.

Usually what happens is, a "crumb" gets torn OFF one of the 4 holes in the "packing glad" and flows down the fuel line and wedges into the float "needle and seat". This happens because of "In-Activity" of the fuel valve handle. IT STICKS to the packing gland, and tears when moved 2 years later!

Be certain to use metal polish on a 'Q'-tip to "polish" the brass float valve seat!!!!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #10 of 47 Old 06-10-2016, 11:00 PM Thread Starter
1st Gear
 
Join Date: Jun 2016
Posts: 21
ok brilliant. tje previous owner did say that he cleaned the carb after it had sat for a while just before i bought it. i peronallylike the idea of a manual valve if it is in fact better than the vaccum valve.

Sent from my SPH-D710 using Tapatalk
phihallklr650 is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Need Help With Airbox Rebel_2006 1987 to 2007 Wrenching & Mods 5 01-13-2015 01:09 PM
Can't get fuel to drain twinblown 2008+ KLR650 Wrenching & Mod Questions 16 07-20-2014 04:45 PM
Fuel starve at load, air in fuel line, tank vacum? troutbum33 1987 to 2007 Wrenching & Mods 11 08-21-2012 08:52 AM
Oil in the airbox? Lockjaw KLR & Other Motorcycle Related Discussion 12 10-09-2010 04:59 PM
Oil in Airbox JFLecours 1987 to 2007 Wrenching & Mods 1 05-25-2007 09:16 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome