Picked up KLR650 Project questions - 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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post #1 of 102 Old 05-10-2018, 11:00 PM Thread Starter
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Picked up KLR650 Project questions

Greetings,

I have a few questions about my 2005 KLR 650 project I just picked up.

The fuel system was completely removed and I have to put the tank and all the lines back on, I have searched but not found what one of the lines I have in the box from the previous owner is, its some clear rubber hose, its stained sort of rust color.

Also, I am new to KRLs in general, what is the second throttle cable used for? This one needs a new grip assembly and while I could just order a bunch of OEM parts, I was wondering if there were newer offerings that work well.

Last question, on top of the coolant reservoir there is another tube, what is the purpose of this tube and how was it routed through the bike?

Thanks in advance, I have gotten the bike to start briefly on carb cleaner after completely redoing the wiring harness, this was very exciting but it still has a long way to go before I get to take it for a spin!
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post #2 of 102 Old 05-11-2018, 10:55 AM
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There are only 2 translucent hoses used as stock & standard parts on a KLR650. 1st one is a 12-18 inch long 1/4" diameter carburetor float bowl air vent on the upper LH side, route it down along the shock spring.
The second one is only a 3/16 x 3 inch section which attaches the flooded cell battery nipple to the larger black rubber hose, which passes thru the RH forward tip of the rear inner fender and then thru the wire hose retainer on top of the swingarm.

The standard Keihin CVK40 carburetor has a throttle plate with a light weight spring, to ensure capability of closure in the event of cable fraying or damage they used a opening & closing cable.

The top coolant tank Vent Hose routes to the LH side of the frame spine & CLEAR back to the Left Rear turn signal/Tail light area. Keeps any slippery coolant off of tire tread.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 102 Old 05-11-2018, 11:11 AM Thread Starter
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Great information, I really appreciate it, after some further research it appears I am missing some pieces to my fuel system, I have no t fitting, and my tank only has one top fitting, I also seem to be missing some sort of canister that I believe is for overflow fuel. If anyone has and good diagrams about routing these hoses or even just some good pictures of how their stuff is routed that would be great. The manual I was given with this bike is not the FSM and does not contain any of this information so if anyone has that as well that would be great. This bike seems to be missing quite a few little bits here and there which is what I expected since multiple people have been playing around with this from what I gathered. I'm really excited to ride this thing as I alway wanted an enduro style bike after growing up with dirt bikes for most of my life.
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post #4 of 102 Old 05-11-2018, 12:16 PM
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Quote:
Originally Posted by darkipod View Post
...I have no t fitting, and my tank only has one top fitting, I also seem to be missing some sort of canister that I believe is for overflow fuel. ....
I'm not sure what T-fitting you are referring to, but the other things you mention are related to the vapor recovery system. There were two versions. The California version had two fittings at the back of the tank, the 49-state only one.

The stuff is often removed, either to un-complicate things or under the mistaken impression that it will improve things. In either case, the bike will work fine without it provided that the airbox is properly plugged, if necessary, and that the tank vent is not plugged.

I refer you to this site: MarkNet - KLR650 as it may be helpful. It sounds like yours is a 49-state version, so 'De-Californization" is not quite accurate, but the diagrams may help.

What can help us is pictures of what you're dealing with. You need 15 posts and a hosting service to embed pictures, and you can always attach them to the post if you don't have a hosting service.

I'd be happy to help with posting pictures for you; just drop me a PM and I'll get you my e-mail address. You can send me the photos and I'll get them into your post.

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #5 of 102 Old 05-11-2018, 02:52 PM Thread Starter
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Great! I will get some pictures right away I usually use imgur to upload images so I will do that an send you a link so that you can put the link into the thread.
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post #6 of 102 Old 05-11-2018, 06:57 PM
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Oh my.

darkipod asked me to post this imgur link: https://imgur.com/a/1V4YL76

I saw so many things that I think, in order to provide good help, it might be better to embed the images so that people can comment directly to an image.

#1


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Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #7 of 102 Old 05-11-2018, 07:06 PM
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#9


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Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #8 of 102 Old 05-11-2018, 07:12 PM
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#17


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Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #9 of 102 Old 05-11-2018, 07:13 PM
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#24


#25

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #10 of 102 Old 05-11-2018, 07:28 PM
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Let's try to do it like this: Give the picture number and what you see wrong or identify the part shown, explaining what it is and where it goes.

For example,

#1, Tank pucks are missing. They are round rubber things that mount to the bosses on the frame at the center of the picture. They locate the tank. Should be one on each side.

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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