gas - 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 4 Old 10-06-2009, 09:48 PM Thread Starter
Join Date: Oct 2009
Posts: 3

I am clueless on this. I have a 2007 and was changing the spark plug and battery. I removed the fuel tank with the attached friction barb. I removed it to have easier access to change the spark plug.

Now it runs, but is leaking fuel out of the overflow hose. It only leaks if the choke is off. It doesn't leak if the choke is on. But it leaks alot of fuel.

When I removed the fuel tank. I pulled the friction barb tube out all the way. I have no idea if that tube just sticks out on the bottom of the bike where the overflow tube is.

Any suggestions?
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post #2 of 4 Old 10-07-2009, 09:50 PM
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Location: Paso Robles, CA.
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The tubes connected to the back of the tank are color coded, one red, one blue. The lines connecting to the petcock are two different sizes. The larger of the two connects the fuel outlet on the right to the carb. The smaller line is a vacuum line which connects to the back of the petcock and a T in the vacuum line.
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post #3 of 4 Old 10-07-2009, 10:55 PM Thread Starter
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Problem solved. It turned out to be that my carb needed cleaning. The pilot jet was clogged. Now it runs like a charm.

Thanks for the help.
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post #4 of 4 Old 03-30-2010, 09:30 PM
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Join Date: Mar 2010
Location: Central Maine
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I think it may have been a jammed float valve, as a clogged pilot jet would not make it leak out of the overflow. Also, the fact it does not leak when you had the choke on may have been because it was putting a large vacuum on the jet so that it sucked gas through the engine instead of leaking out the overflow. Someone please verify the accuracy of what I just said. Thanks, Will
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