Help identifying dangling tubes - Kawasaki KLR 650 Forum
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post #1 of 11 Old 07-06-2015, 02:21 PM Thread Starter
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Question Help identifying dangling tubes

Hello all! First, lemme say preface this post that I don't know much about the mechanics of bikes. Here's my issue: I was washing my bike just now (a 2004 KLR) and a black tube fell out of the bike's bowels. No clip or fasteners appear to have fallen off, either. I know that there are supposed to be some dangling tubes below the bike, but I'm not sure how many there are supposed to be and what all their functions are.

In addition to the tube that fell off just now, there are two more tubes hanging down and ziptied near the brake pedal. All of them are black. I will refer to them as tubes #1, #2 and #3, with tube #1 being the one that fell off.

One of them, tube #2, is capped (I assume this is the drain tube for the air filter oil, based on poking around previous posts about hanging tubes). It's about the same diameter as tube #1.

Tube #3 is not capped and slightly larger in diameter than the other two tubes. No idea what this tube is for.

My questions: What are all these tubes for? Are there supposed to be three dangling tubes? Or was the one that fell off supposed to be connected at both ends? What does this one go to and where do I need to poke around to reconnect it? Do I even need to worry about reconnecting it?

Thanks for your help in advance!
-Ian Campbell

EDIT: Just realized I posted this in the wrong forum! Deleting doesn't seem to be possible. Sorry, first post on the forum!

Last edited by itcampbell; 07-06-2015 at 02:25 PM.
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post #2 of 11 Old 07-06-2015, 02:48 PM
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Quote:
Originally Posted by itcampbell View Post
One of them, tube #2, is capped (I assume this is the drain tube for the air filter oil, based on poking around previous posts about hanging tubes). It's about the same diameter as tube #1.

Tube #3 is not capped and slightly larger in diameter than the other two tubes. No idea what this tube is for.
The three dangling tubes go to the following (parts listed are for a 1995, which is what I have):

Carb, part 92059A (I think?):

http://www.kawasakioemparts.com/oemp...carburetor-1-3

Airbox, part 50144:

http://www.kawasakioemparts.com/oemp...70/air-cleaner

Battery, part 703:

http://www.kawasakioemparts.com/oemp...ical-equipment

I still have a battery tube on mine, but my battery is sealed so the tube's just sitting there open at both ends. The way the battery one routes for me makes it seem unlikely that it would just fall off; indeed, it has gone thousands of miles not attached to anything, and stays well-put.

On the carb, look on the left side and see if there's a 90 nipple just hanging out on its own.

Let us know what you find; always curious about things like this.

Last edited by beejjorgensen; 07-06-2015 at 02:55 PM.
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post #3 of 11 Old 07-06-2015, 03:35 PM Thread Starter
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Thanks for the reply! I don't see any bare nipples on the left side, or anywhere else (but I haven't removed the seat or anything yet, either, for what it's worth.. I would imagine, probably erroneously, that the places where hoses connect aren't too hidden). The nipple you wanted me to check out is the one coming off the side of a my fuel lever, right? Nope, that guy's accounted for.

Based on the info you provided me, I bet it is the battery hose. Two years ago I replaced the stock battery with a sealed one. Had it replaced, rather, and I'm not sure how the dudes who replaced it had it connected on there or whether they even left it fastened on. But assuming they did leave it just hanging out would explain why I can't find any place that's missing a hose, and would explain why it jostled off so easily. I've put about 8K miles on it in that time.

Thanks for your help!!
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post #4 of 11 Old 07-07-2015, 11:26 AM
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You did not mention #4 that goes to the rear of the gas tank under the front nose of the seat. It is the vent line for the gas tank. I wonder about it's value since on non-California models the exterior nipple on the gas cap that connects to the part of this line inside the tank is not sealed.
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post #5 of 11 Old 07-07-2015, 11:58 AM
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Quote:
Originally Posted by itcampbell View Post
Thanks for the reply! I don't see any bare nipples on the left side, or anywhere else (but I haven't removed the seat or anything yet, either, for what it's worth.. I would imagine, probably erroneously, that the places where hoses connect aren't too hidden). The nipple you wanted me to check out is the one coming off the side of a my fuel lever, right? Nope, that guy's accounted for.
Not that one (that one's the vacuum to the petcock), but this one off the carb, attached to this point:



(Someone correct me if I'm wrong, but I think that's the one that routes down, not back.)

I have the T-mod in there, so your tube routing might be slightly different.

The battery tube is on the side of the battery, like so:



Hopefully that's the one that's gone missing.
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post #6 of 11 Old 07-07-2015, 12:03 PM
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Originally Posted by GoMotor View Post
You did not mention #4 that goes to the rear of the gas tank under the front nose of the seat.
True. If nothing else pans out, the OP can take the seat off and quickly see if there's nothing attached to the rear of the tank.

Once I had a fuel hose on one of those split open. Things were getting damp with gas from sloshing a full tank. Fun. Sliced it down and managed to create enough slack to get it reattached, salvaging the weekend.
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post #7 of 11 Old 07-07-2015, 07:42 PM Thread Starter
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Originally Posted by beejjorgensen View Post
True. If nothing else pans out, the OP can take the seat off and quickly see if there's nothing attached to the rear of the tank.

Once I had a fuel hose on one of those split open. Things were getting damp with gas from sloshing a full tank. Fun. Sliced it down and managed to create enough slack to get it reattached, salvaging the weekend.
OK, so the battery hose is still firmly secured, so that's not it (thanks for the pictures). But thanks GoMotor for mentioning hose #4. I pulled up the front nose of my seat without even taking it off to take a peak. A hose is supposed to be attached onto a little metal nub coming right off the back of the gastank, isn't it? And hang down through a hole? Yeah, that's the missing hose's connection. Nothing is connected to that nub on my bike.

Now, reattaching. Is this just supposed to hang down through that hole there, or does it need to attach to something or be secured in a specific spot?

Thanks all!
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post #8 of 11 Old 07-07-2015, 08:39 PM
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Quote:
Originally Posted by itcampbell View Post
OK, so the battery hose is still firmly secured, so that's not it (thanks for the pictures). But thanks GoMotor for mentioning hose #4. I pulled up the front nose of my seat without even taking it off to take a peak. A hose is supposed to be attached onto a little metal nub coming right off the back of the gastank, isn't it? And hang down through a hole? Yeah, that's the missing hose's connection. Nothing is connected to that nub on my bike.
You just have one attachment at the back of the tank, yeah, not two? (My bike is equipped with CEB (California Emissions Bullshit), so I get two tubes out the back.)

I don't actually know how that routes on a non-CEB bike. GoMotor?
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post #9 of 11 Old 07-07-2015, 09:12 PM
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The vent tube from the back of the tank just hangs down with the other open ended tubes and is open at the end.

I think the idea is that if any liquid gas gets past the little valves of the vent system in the gas cap, it will go through the little nipple on the right under side of the cap into the internal line in the tank and out the back and down to the ground.

The catch is that on non California bikes that nipple is not sealed and the leaked gas can go wherever gravity and the wind take it. On California bikes it is sealed and the piping leads into a vapor recovery pollution control system.
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post #10 of 11 Old 07-08-2015, 02:40 AM
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