Blue and Red hoses going to fuel tank klr 2016 - 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 27 Old 06-01-2017, 11:58 AM Thread Starter
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Blue and Red hoses going to fuel tank klr 2016

I took off the seat, then fuel tank on my klr 650 2016 to install crash bars. I did not remember which hose went to which blue or red fitting on the tank when putting back together. I guessed, put it all together, and the bike started with choke on for 5-8 seconds and stalled when I shut off the choke off. It will not start now. Could it be from whatever these hoses do? Did I do damage? Thanks!
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post #2 of 27 Old 06-01-2017, 12:02 PM
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Sounds like it ran out of gas. Did you hook up the vacuum line to the petcock?

If that's not it, Could try swapping those 2 colored lines. Mine have a colored dot on each to match the tank.

2016 KLR 650
2017 BMW S1000RR (traded in for
2018 Ducati V4S
1983 GL1100 Goldwing
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post #3 of 27 Old 06-01-2017, 12:08 PM Thread Starter
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Yes, I connected the petcock hose and turned the fuel to on. The tank is full of gas. This morning I quickly swapped the blue and red but it didn't start. Didn't have time to mess around this morning. Big question, will it harm the bike if the b and r lines are switched? I don't even know what they do. I did blow through a tube this morning and has blue out from somewhere in the area.
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post #4 of 27 Old 06-01-2017, 12:10 PM Thread Starter
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"Fuel blew out from somewhere". Typo on last message.
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post #5 of 27 Old 06-01-2017, 01:29 PM
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If nobody replies before I get off work I'll have a look where those lines go. What year is your bike?
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2016 KLR 650
2017 BMW S1000RR (traded in for
2018 Ducati V4S
1983 GL1100 Goldwing
2017 Yamaha R1
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post #6 of 27 Old 06-01-2017, 01:31 PM Thread Starter
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2016. I can't send pictures of it, being a newbie.
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post #7 of 27 Old 06-01-2017, 01:36 PM
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The petckoc has two hoses. One of gas and the other one of vacuum. When I first disassemble the fuel tank just disconnect the gas line and pulling the tank to remove it, the vacuum line that I had not seen is released. When I reassembled I connected the gas line and the motorcycle started for a few seconds and went out. Once I connected the vacuum line turned on normally.
This may be happening. It was my experience. Maybe it help.

The man on top of the mountain didnít fall there.
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post #8 of 27 Old 06-01-2017, 02:00 PM Thread Starter
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I never noticed a second line to the petcock. I will take a look. This is the second time I removed the tank. First time months ago, no issues.
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post #9 of 27 Old 06-01-2017, 02:21 PM
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My bike is also 2016. According to the service manual the red goes to the right is the return and the blue to the left is the vent. This is for California model.

The man on top of the mountain didnít fall there.
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post #10 of 27 Old 06-01-2017, 02:48 PM Thread Starter
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red-right-return.... they are using navigational sea terms!?

Does the book say where the blue hose ends up and the red hose on the otherend so I can determine which hoses go to which color?

Thank you
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