Any one have a step by step for pulling the tank on a 2011? - 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 11 Old 04-25-2013, 09:07 PM Thread Starter
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Any one have a step by step for pulling the tank on a 2011?

My 2011 KLR that I traded for did not come with a service manual and I am going to order one but want to get some electrical stuff hooked up and was hoping to pull the tank to run my wires. Anyone walk me through it step by step? I have taken off the Seat already and see the 2 tank bolts there by the front of the seat. I know I need to unhook the fuel line and what others bolts will I need to undo? Thanks..
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post #2 of 11 Old 04-25-2013, 09:20 PM
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Take off the seat, take out 2 bolts at the rear of the tank, then you have 2 lines at the rear of the tank (on California models, only 1 on 49 state models I believe) then you have a vaccumn line & a fuel line on the petcock. After that it comes off by lifting the seat end & pull it back towards where the seat was. Be careful it's a bit on the heavy side when it's full, not unmanageable but don't drop it. Hope this helps.
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post #3 of 11 Old 04-25-2013, 10:52 PM Thread Starter
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Quote:
Originally Posted by jmabbott888 View Post
Take off the seat, take out 2 bolts at the rear of the tank, then you have 2 lines at the rear of the tank (on California models, only 1 on 49 state models I believe) then you have a vaccumn line & a fuel line on the petcock. After that it comes off by lifting the seat end & pull it back towards where the seat was. Be careful it's a bit on the heavy side when it's full, not unmanageable but don't drop it. Hope this helps.
Sounds like I was getting close. Not sure why there would be any vacuum lines or electrical lines on the tank though. That seems weird. I will have to take a look at it in the morning.

Thanks
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post #4 of 11 Old 04-25-2013, 11:23 PM
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The petcock runs off vacumn, don't have to shut the petcock off all the time. On the otherhand there have been reports of problems with it when the diapham goes out no gas to the carb & you are stuck. Some have gone & put a different petcock on to keep this from happening. This is about the 1st gen bikes but the 2nd gen is the same idea. http://www.klrforum.com/showthread.p...hlight=petcock
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post #5 of 11 Old 04-25-2013, 11:59 PM
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Watch out for the two rubber "pucks" the tank sits on. They're easily dislodged and misplaced.

Also, it's possible to crack your fairings if you try to squeeze the tank through them without removing them. It can be done, but be careful, especially putting it back on.

Don't ask me how I know these things.



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post #6 of 11 Old 04-26-2013, 02:52 AM
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You may not have to remove the tank just to install a fuse block; however, if you run additional auxiliary wires forward, much easier with the tank removed.

Be careful with wire routing, avoiding abrasion and pinch points to the maximum extent.
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post #7 of 11 Old 04-26-2013, 06:42 AM
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Quote:
Originally Posted by planalp View Post
Watch out for the two rubber "pucks" the tank sits on. They're easily dislodged and misplaced.
+1

They can bounce/roll an incredible distance away from where you're working. I put a good dollop of RTV into the hole then push them back onto the pin to keep from having to call out the search party ever again.

Gray-haired riders donít get that way from pure luck.

Unknown
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post #8 of 11 Old 04-26-2013, 09:17 AM
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Quote:
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+1

They can bounce/roll an incredible distance away from where you're working. I put a good dollop of RTV into the hole then push them back onto the pin to keep from having to call out the search party ever again.
Now there's a good idea. I'll do that the next time I take the tank off.



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post #9 of 11 Old 04-26-2013, 08:49 PM Thread Starter
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Got it done. Didn't get the Fuse block installed because I haven't had time to order one yet. In the meantime I just ran a Fused 10g wire straight off the batter to the handlebars with 1 SAE plugs. Then I made a couple pigtails for some Cigarette lighters to SAE and then I wired up my Garmin Montana rugged mount with an SAE plug on the end so I can power that. Matter of fact I may just leave it like it is for now and see if the need arises for me to add more electrical. If I do I will order up the fuse block. Thanks for all your help.
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post #10 of 11 Old 04-27-2013, 12:30 PM
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You're GOLDEN, for the moment, lacofdfireman!

Fuse block? Later, perhaps; much, much later . . .
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