2005 Gen 1 Fuel Tank Venting?? - 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 13 Old 05-01-2020, 03:16 PM Thread Starter
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2005 Gen 1 Fuel Tank Venting??

I finally have a good question to post to the group. I've removed just about everything on my California version of the good ole KLR 650 relating to emission control crap. I also had my tank off for awhile, cleaning up the mess from leaving California fuel in the tank and carburetor way too long. I have finally finished doing everything I can think of and now I'm putting it all back together. My fuel tank has Two Vent tubes that exit the tank near the two hold down bolts. Do both tubes need to have hoses attached and routed down and out?
I can't seem to figure what they really do but can only guess. I'm dying to get riding again! The passes just might be open?

Thanks Everyone!
Fred Weaver
Sutter Creek, CA
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post #2 of 13 Old 05-01-2020, 04:11 PM
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....I no longer use the factory tanks and my IMS tanks don't have either. IIRC one is the tank vent and the other is the overfill tube that drains fuel when you get some in the filler cap neck area. both should be routed down and out but the bike will run fine without.

Dave
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post #3 of 13 Old 05-01-2020, 04:24 PM Thread Starter
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Thanks Dave!!! Damn, That just makes so much Sense. I appreciate your input and now I'm going to go get er done!
Thanks,
Weav
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post #4 of 13 Old 05-01-2020, 05:21 PM
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Quote:
Originally Posted by Weav View Post
I finally have a good question to post to the group. I've removed just about everything on my California version of the good ole KLR 650 relating to emission control crap. I also had my tank off for awhile, cleaning up the mess from leaving California fuel in the tank and carburetor way too long. I have finally finished doing everything I can think of and now I'm putting it all back together. My fuel tank has Two Vent tubes that exit the tank near the two hold down bolts. Do both tubes need to have hoses attached and routed down and out?
I can't seem to figure what they really do but can only guess. I'm dying to get riding again! The passes just might be open?

Thanks Everyone!
Fred Weaver
Sutter Creek, CA
I have a Gen II but I think the tank nipples you are questioning are the same as Gen I. I vent the nipple/connection on the tank that is closest to the longitudinal center of the bike via a tube oriented down toward the ground. This is sometimes referred to as the "blue" connection. The outboard or "red" connection on the tank is capped off. On California models, both these connections are tubed to a separator.

Jason
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Last edited by Norton 850; 05-02-2020 at 08:32 AM. Reason: Reversed the colors
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post #5 of 13 Old 05-01-2020, 09:11 PM
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The more Center nipple is BLUE & leads to the fuel cap VENT Nipple, if I am not mistaken, blow thru it, You will discover which nipple leads to where.

Two hoses towards the ground near the rear brake pedal pivot would be safe.

pdwestman
Modify at "YOUR OWN RISK"!

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post #6 of 13 Old 05-01-2020, 11:16 PM Thread Starter
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Tank Venting.....

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Originally Posted by pdwestman View Post
The more Center nipple is BLUE & leads to the fuel cap VENT Nipple, if I am not mistaken, blow thru it, You will discover which nipple leads to where.

Two hoses towards the ground near the rear brake pedal pivot would be safe.
You know? Sometimes the most obvious simply passes us by...... Yep, I did hook up some hoses and blew thru them. Of course, all the obvious answers were realized. The "Blue" tube goes up to the Tank Cap and the "Red" tube is the actual tank vent. The Good news is I have now got it all plumbed back up and the tank is sorta bolted into place. I have to find a couple washers in the morning so I can bolt the tank down to the frame. I have plenty of hose material all routed nicely and the tank will only take me a few minutes to finally bolt down. Thanks fellas for all the help. Thank God, I have all the Cali BS removed and boxed up just in case someone needs to have it down the road. I am so jazzed to have my motorcycle back and looking for some riding in the next few days. I still have that MONUMENTAL task of getting my DMV stickers up to date even though this fricken state has all the DMV offices OFF LIMITS...... This CV BS is just that...... BS. Time to open up the State and businesses..... Yep, I'm wound up...... Have Fun everyone,
Weav
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post #7 of 13 Old 05-02-2020, 08:36 AM
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Oops, I got my colors backwards so I corrected my post.

I apologize for the confusion.

Jason
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post #8 of 13 Old 05-02-2020, 08:54 AM Thread Starter
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Oops, I got my colors backwards so I corrected my post.

I apologize for the confusion.

Jason
Jason, it was no problem at all... And you got me going in the right direction. Once I blew thru the tubes and figured out where they were going, it made setting it up very simple. The other thing I should have mentioned was that I found the complete "System Schematic" on the inside of the Left Side cover. It showed all the California Emission baloney and how it was plumbed! I had removed all that junk back in 2005 when I bought the bike brand new. I hope to be riding it around the airport where I keep it today by noon. I've had the bike on a Non Op status for a few years, so I still need to pay a couple bucks to the DMV before I can take it out on the roads here. Won't Be Long!!!!
Thanks again,
Fred Weaver
Sutter Creek, CA
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post #9 of 13 Old 05-02-2020, 11:27 AM
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You know? Sometimes the most obvious simply passes us by...... Yep, I did hook up some hoses and blew thru them. Of course, all the obvious answers were realized.

..... Yep, I'm wound up...... Have Fun everyone,
Weav
I'll ask if the large emissions hose Elbow into the clean-side of the air box is PLUGGED to keep the dust out?

pdwestman
Modify at "YOUR OWN RISK"!

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post #10 of 13 Old 05-02-2020, 01:24 PM
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I'll ask if the large emissions hose Elbow into the clean-side of the air box is PLUGGED to keep the dust out?

Good thought!

I plugged mine by inserting a rubber cap into the elbow and then snugging it with a zip-tie.

Jason
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