My Eyes are playing tricks on me & I'm baffled!!! Help Me!! - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 12 Old 07-01-2011, 12:22 AM Thread Starter
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My Eyes are playing tricks on me & I'm baffled!!! Help Me!!

So I got my SW Motech Crash Guards & Bash Plate along with some Bark Busters. Man it was tough but I did it. I did run into isssue with the install. It was tight. My orginal skid plate bolts were not long enough & niether was SW Motechs. So I'm short one bolt. No problem there.
Here is where ya'll are going to think I'm an idiot. I'm reinstalling my tank & I go to hook up my fuel lines. There is only one. There's a larger line. it goes to the carb...I think The other one which is smaller....the reserve? Go ahead & laugh. This is the reason I bought this bike. I want to work on my own bike.
I can't find the smaller one. It is gone!!!!! I looked & looked!!! the SOB grew legs & walk off or it's like a king snake in the woods hiding in the tall grass!!
For the love of God will someone show me or tell me where to locate it. So I can ride my bike!

Thanks

If you're gonna be a Bear.......be a Grizzly!
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post #2 of 12 Old 07-01-2011, 12:33 AM
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Light Train -

That would be the petcock vacuum line. It should be coming off of a vacuum fitting towards the front of the carburettor. If it has fallen off you will see a naked brass nipple. Pause.

OK, couldn't resist that, but it's true. If it has fallen off you can replace it with a short bit of vacuum hose. Without it your petcock will not allow gas to flow (I bet you already know that).

Look at this post of vatrader's most excellent pictures and diagrams. In the top diagram, the hose in question is marked by number 36/390.

T

Tom [email protected]

“The muzzle of the Luger looked like the mouth of the Second Street tunnel, but I didn’t move. Not being bullet proof is an idea I had had to get used to.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 07-01-2011 at 12:38 AM.
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post #3 of 12 Old 07-01-2011, 12:42 AM
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Quote:
Originally Posted by Light Train View Post
So I got my SW Motech Crash Guards & Bash Plate along with some Bark Busters. Man it was tough but I did it. I did run into isssue with the install. It was tight. My orginal skid plate bolts were not long enough & niether was SW Motechs. So I'm short one bolt. No problem there.
Here is where ya'll are going to think I'm an idiot. I'm reinstalling my tank & I go to hook up my fuel lines. There is only one. There's a larger line. it goes to the carb...I think The other one which is smaller....the reserve? Go ahead & laugh. This is the reason I bought this bike. I want to work on my own bike.
I can't find the smaller one. It is gone!!!!! I looked & looked!!! the SOB grew legs & walk off or it's like a king snake in the woods hiding in the tall grass!!
For the love of God will someone show me or tell me where to locate it. So I can ride my bike!

Thanks

The small line is a vacuum line to open the petcock when the motors running. It comes off a tee on the intake side of the carb and goes to the back of the petcock.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #4 of 12 Old 07-01-2011, 07:55 AM Thread Starter
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Ok the fat line Comes of the Front side T of the Carb (The Front of the Bike) it's there. The small line I cn't find. I've looked at the Diagram which appears to come of the left side of the carb?? I can't see any brass nipples or unconnected hoses. The only brass fitting I see is the one comming off the petcock valve. This is one of the stranges things!!!!!

If you're gonna be a Bear.......be a Grizzly!
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post #5 of 12 Old 07-01-2011, 07:58 AM Thread Starter
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Tom
36/90 is there. It's the smaller line that connects to the brass fitting on the Petcock Valve.

Quote:
Originally Posted by Tom Schmitz View Post
Light Train -

That would be the petcock vacuum line. It should be coming off of a vacuum fitting towards the front of the carburettor. If it has fallen off you will see a naked brass nipple. Pause.

OK, couldn't resist that, but it's true. If it has fallen off you can replace it with a short bit of vacuum hose. Without it your petcock will not allow gas to flow (I bet you already know that).

Look at this post of vatrader's most excellent pictures and diagrams. In the top diagram, the hose in question is marked by number 36/390.

T

If you're gonna be a Bear.......be a Grizzly!
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post #6 of 12 Old 07-01-2011, 09:58 AM
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You're not being clear.

You say the fat line is there and you can't find the small line. Then you say 36 is there, which is the small line.

When you say fat line are you referring to the fuel line?

For clarity, the lines coming off the carb should be:

A vent line, unmistakable as it is clear.
A fuel line, which comes off the left side.
A vacuum line for the petcock, which comes of a fitting on the front.
A vacuum line for the air injection, which comes off the same fitting on the front.


I'm not sure what hose you're missing.

T

Tom [email protected]

“The muzzle of the Luger looked like the mouth of the Second Street tunnel, but I didn’t move. Not being bullet proof is an idea I had had to get used to.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem
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post #7 of 12 Old 07-01-2011, 10:42 AM
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Good morning.



A grainy picture of a petcock. Visible is the larger of the two lines that attach to the petcock. This line [fuel line] will run to the bottom left [towards the back wheel] side of the carburetor. It is pretty well hidden behind a relay. Make that very well hidden.



If that ain't it, there's only one more option...



This is the smaller of the two hoses that attach to the petcock. This one is the vacuum line. It runs to the engine side of the carburetor, to the top of the round housing the rubber manifold boot attaches to.



Looking from the right [rear brake pedal side], you'll see the vacuum line. Sorry for the fuzzy photos. Fighting to stay on the trailing edge of technology comes at a price. Sadly, this is an example of one of those prices.

This line is like a Camelion. If the end you are looking for is facing away from you, it will blend. Trace it from the right side of the bike.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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post #8 of 12 Old 07-01-2011, 10:44 AM
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I'm also not clear on what you are looking for...The hose itself, that will attach to the petcock, or what the hose from the petcock will attache to on the carburetor?

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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post #9 of 12 Old 07-01-2011, 11:14 AM
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I don't know if I'm helping here or not, but here's a picture of the fitting.
It's taken from just forward of the petcock. You'll note both my naked
brass nipples are covered with vacuum caps. Modesty in all things...

They are covered because I have neither an air injection nor vacuum
petcock fitted.

The fuzzy black pipe in the foreground is the oil pipe going up to the head,
and the curved black pipe is the choke fitting.



This fitting is what you should find your vacuum line for the petcock attached to.

The back of it is easily seen from the right side.



T

Tom [email protected]

“The muzzle of the Luger looked like the mouth of the Second Street tunnel, but I didn’t move. Not being bullet proof is an idea I had had to get used to.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 07-01-2011 at 11:24 AM.
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post #10 of 12 Old 07-01-2011, 11:46 AM
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Light Train, how did you get your Bark Busters on?? I found them rather difficult and gave up. Could you possibly post a photo show how you mounted them??

Thanks

Erik
2003 Bandit 1200S
2009 KLR 650

74 Honda CB360
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