California Smog Removed - Kawasaki KLR 650 Forum
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post #1 of 17 Old 08-08-2012, 08:30 PM Thread Starter
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California Smog Removed

I just wanted to share because my bike runs great! In fact it's kinda unbelievable to me. I didn't realize I had such a big problem.

Here's what I think the situation was. The smog crap was malfunctioning and causing the gas tank to be under a vacuum condition. I also now have a direct vacuum line to the petcock, which may in my opinion be more efficient than when it was tee'd off for the smog canister. I also plugged the tank vent line on the right side of the tank and ran a new line out the bottom for the left side tank vent.

Well I refer to the experts for any another opinions, but one thing for sure is shes getting the gas now.
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post #2 of 17 Old 08-09-2012, 11:02 PM
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Originally Posted by CraigES View Post
I just wanted to share because my bike runs great! In fact it's kinda unbelievable to me. I didn't realize I had such a big problem.

Here's what I think the situation was. The smog crap was malfunctioning and causing the gas tank to be under a vacuum condition. I also now have a direct vacuum line to the petcock, which may in my opinion be more efficient than when it was tee'd off for the smog canister. I also plugged the tank vent line on the right side of the tank and ran a new line out the bottom for the left side tank vent.

Well I refer to the experts for any another opinions, but one thing for sure is shes getting the gas now.

What symptoms did you have that led you to the smog stuff? Was there gas in the charcoal canister?

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 #3 of 17 Old 08-10-2012, 09:08 AM Thread Starter
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Spec,

I had been feeling some surging on hard acceleration and highway speeds. A few times I ran out of gas and would have to switch to reserve early. Then at fill up it would only take about 3-1/2 gallons.

I did suspect the venting, because I've read stories of guys blowing out the vent lines.
Other than that I didn't have a specific reason to suspect the smog equipment. The side covers and seat were off the bike and as I was looking it all over, I decided to go for it, figured it would be easy to undo if it made the bike run poorly.

At the time I didn't check the canister for gas, whet out and check it just now, no gas present.
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post #4 of 17 Old 08-11-2012, 07:52 PM
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My bike is surging at constant speeds also. I think I am going to remove the Cali crap this weekend if I can find the time. I will post how it works out.
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post #5 of 17 Old 08-12-2012, 05:45 AM
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I know removing emissions related components is a touchy subject for some. My KLR is a Federal model and not subject to the California requirements. However I also have a KTM that is euro spec and I "killed the octopus" on it for real or imagined reasons. Just keep in mind that one day it may be required to have your bike in OEM condition to be able to register it. You shouldn't do anything in that respect that can't be undone, keeping all the parts, making irreversible changes, etc.

I did do a low buck mod to the exhaust on the KLR cutting out the silencer at the end of the muffler. Should have just bought an aftermarket can keeping the stock muffler intact. Now to get back to stock I would have to buy an OEM muffler or somehow reweld the silencer back in place if ever need be.
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post #6 of 17 Old 09-27-2012, 06:53 PM
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Cool California Smog Removal

This is good news on the removal of the charcoal canister. I live in California and I tore my 09 KLR apart to put on crash bars and noticed the charcoal canister and all the associated lines. I said to myself, this sh** (stuff) is going away, but I was also putting on a FMF Exhaust at the time and did not want to change too much too soon so I could back track stuff if the bike started running or idling funny. I figured once I was content the next option was to remove the canister. Well the bolts on the crash bars rubbed holes in the gas tank so off to the dealer went the bike. The first tank the dealer got in was the 49 state tank and dit not have the two steel hoses coming out from the back of the tank. I said I wanted that one but they would not let me have it since it was not 50 state compliant. This was a California Kawi dealer. Needless to say they could only put a stock California gas tank on my bike. oh well it is what it is but it would have been nice. I also purchased the repair manual and it shows the routing of non California vent lines. Good stuff. I am going to ride it for a while but next oil change baby……………
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post #7 of 17 Old 10-03-2012, 10:14 PM
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Originally Posted by FastRnu2 View Post
This is good news on the removal of the charcoal canister. I live in California and I tore my 09 KLR apart to put on crash bars and noticed the charcoal canister and all the associated lines. I said to myself, this sh** (stuff) is going away, but I was also putting on a FMF Exhaust at the time and did not want to change too much too soon so I could back track stuff if the bike started running or idling funny. I figured once I was content the next option was to remove the canister. Well the bolts on the crash bars rubbed holes in the gas tank so off to the dealer went the bike. The first tank the dealer got in was the 49 state tank and dit not have the two steel hoses coming out from the back of the tank. I said I wanted that one but they would not let me have it since it was not 50 state compliant. This was a California Kawi dealer. Needless to say they could only put a stock California gas tank on my bike. oh well it is what it is but it would have been nice. I also purchased the repair manual and it shows the routing of non California vent lines. Good stuff. I am going to ride it for a while but next oil change baby……………
Just take the stuff off and save it as suggested. The best thing I did was remove the AIS junk and my ride doesn't splutter poppity pop all the way down a hill anymore. Now sounds like a fine tuned pressure washer!
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post #8 of 17 Old 10-05-2012, 11:51 AM
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Just take the stuff off and save it as suggested. The best thing I did was remove the AIS junk and my ride doesn't splutter poppity pop all the way down a hill anymore. Now sounds like a fine tuned pressure washer!
I need to change the battery this weekend on the KLR and modify the plastic slightly for the FMF exhaust. I will talke this opportunity to remove the charcoal canister but you also mentioned the AIS which is the Air Injection System. You are telling me I need to remove it also? Is there any special aftermarket parts required to do this? I am stuipid this is my first KLR.

I am also going to change all the fluids on the 06 Yamahog Road Star.
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post #9 of 17 Old 10-05-2012, 02:36 PM
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post #10 of 17 Old 10-05-2012, 03:01 PM Thread Starter
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Originally Posted by FastRnu2 View Post
I need to change the battery this weekend on the KLR and modify the plastic slightly for the FMF exhaust. I will talke this opportunity to remove the charcoal canister but you also mentioned the AIS which is the Air Injection System. You are telling me I need to remove it also? Is there any special aftermarket parts required to do this? I am stuipid this is my first KLR.

I am also going to change all the fluids on the 06 Yamahog Road Star.
To remove the Air Injection System you will need a block off plate. I believe you can purchase from Eagle Manufacturing. The only benefit from removing AIS, I know of is, it reduces back fire. Worked on mine. The AIS can be left in place, while everything else, charcoal canister and such, can be removed and saved.

By the way my bike still runs great.
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