Spitting n sputtering? Thoughts? - 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 22 Old 12-30-2018, 05:10 PM Thread Starter
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Hi, I went and rode the bike to the local WMA today, to check it out in the sand. I took it real easy, just to see, how the bike reacted in sand. I grew up riding on trails, sand etc., but that has been 40+ years. After 30 minutes, I went to pull out, and noticed the bike sputtering pretty badly. It cleared up, after 1/4 mile or so. I thought it was like dirt was getting in, through the air cleaner area, but all seems good. Then, I noticed the threads about the air box, clean side tube. Damn, if I can find it....i took some pics, and will attach them. I did see 2 duck bill stubs and 1 other tube, but nothing with a plug, in the area, that the clean side tube should be. Any suggestions, about how to proceed from here? And where the heck should I be looking, since I say, no place where this tube should reside.

Last edited by Pbk16gt; 12-31-2018 at 08:29 AM.
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post #2 of 22 Old 12-30-2018, 06:28 PM
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https://www.souperdoo.com/stuff%20th...-zerk-fittings

Scroll down and look at the second picture. This is the bottom of the clean-side tube and, up to 2011, they put that bottle in the line. After that, there is simply a plug int he bottom of the tube.

This picture was taken from where the swingarm would be if it hadn't been removed.

If you are concerned about this you should check to see that the tube is attached up at the airbox and that the plug is in place at the bottom.

Now, a different topic. Did you dump the bike? On the Gen 2 bikes it is possible to flood the vent tube with fuel in a tip-over. The vent tube goes up and over the battery area and has a slight dip in it. If the vent tube gets flooded gas can collect there and obstruct the vent tube. That causes the engine to spit and sputter until the vent tube clears. One reason that what Kawasaki did on the Gen 2 was not a fix to the vent tube issue and why the T-Mod is still a good idea.

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post #3 of 22 Old 12-30-2018, 07:02 PM Thread Starter
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Tom, I didn't dump it. Using a flash light, the tubes, I did see are black in color, and no plugs are there. I am assuming when you say plug, it is not capped off, but prevents stuff from getting inside. Is that correct?
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post #4 of 22 Old 12-30-2018, 08:32 PM
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There should be a plastic plug in the bottom of the tube that prevents any stuff from getting in.

You can only just see the plug in the picture referenced above.

It is 92066 in the fiche picture below:

Tom [email protected]

I lit a cigarette and dragged a smoking stand beside the chair. The minutes went by on tiptoe, with their fingers to their lips. -Philip Marlowe

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


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post #5 of 22 Old 12-31-2018, 06:53 AM Thread Starter
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So, that's a 1 way plug? Does it allow air in? I have searched the net , to try and order 1, without success. I found the crank vent tube( large one the runs through a rubber ring and a skinny black one that is beside it) but there is no plug on the skinny one.

Last edited by Pbk16gt; 12-31-2018 at 06:56 AM.
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post #6 of 22 Old 12-31-2018, 07:21 AM
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Originally Posted by Pbk16gt View Post
So, that's a 1 way plug? Does it allow air in? I have searched the net , to try and order 1, without success. I found the crank vent tube( large one the runs through a rubber ring and a skinny black one that is beside it) but there is no plug on the skinny one.
There are a lot of OEM Parts Dealers on the web. I've pretty much limited my shopping for OEM Parts to Rocky Mountain ATV as they seem to regularly offer the lowest price and keep me apprised of delivery status. Also, I had some experiences where an OEM Part provider didn't provide whether an item was on backorder prior to purchase; RMATV shows that status right on their web page.

https://www.rockymountainatvmc.com/

My Service Manual (2008-2016) refers to the large tube that you're missing there as the "Breather Tube." If you do a google search of "KLR650 Airbox Breather Tube," a couple of vids on YouTube will pop up that relate to a mod to that tube...which may be your issue, as in mod-gone-wrong, so to speak. However, the main thing I see that may be helpful is a couple have video of the entire length of the tube so you can see what's going on deep in there.

Good luck!

Last edited by Bill10; 12-31-2018 at 07:26 AM.
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post #7 of 22 Old 12-31-2018, 10:34 AM
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Quote:
Originally Posted by Pbk16gt View Post
So, that's a 1 way plug? Does it allow air in?
Nope, it's a plug, no-way plug. You can stick a bolt in there, you can stick a stick in there, you can double it back and zip tie it, you can stick a ball bearing in there, you can do anything that it takes so that it is not open to the atmosphere.

The line is installed in the intake tract. It has a bit of a vacuum on it. If it is not plugged it can suck up stuff and that goes straight into the engine, so you don't want it to allow anything in.

Its purpose, and the reason they put a bottle on it for so many years, is to collect any fluid that might get into the clean side of the air filter, be it oil, water, puked fuel and provide a means to drain it out. At every oil change (or whatever convenient, regular but fairly infrequent interval such as getting your teeth cleaned or taking a shower) you should remove the plug and drain whatever has collected in the tube.

Tom [email protected]

I lit a cigarette and dragged a smoking stand beside the chair. The minutes went by on tiptoe, with their fingers to their lips. -Philip Marlowe

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


Sting like a butterfly.
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post #8 of 22 Old 12-31-2018, 11:06 AM Thread Starter
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Awesome...i will just plug that sucka...that was easy... I thought I needed it. Thanks...
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post #9 of 22 Old 12-31-2018, 12:34 PM
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Awesome...i will just plug that sucka...that was easy... I thought I needed it. Thanks...
Let me suggest that you read this thread, https://www.klrforum.com/2008-klr650...y-exhaust.html

Then be certain that the hose which you are plugging is indeed attached to the forward nipple of 2 that are on the bottom of the air box, ahead of the rear inner fender.

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post #10 of 22 Old 12-31-2018, 01:02 PM Thread Starter
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Yes, I had read that thread, and another one about the hose. It is the hose that is in the pics below, correct.
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