Over filled at the pump! - 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 21 Old 01-06-2019, 06:36 AM Thread Starter
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Over filled at the pump!

OK, I admit I forgot the warning and overfilled. Within about a mile or so it started the sputter/stutter Ive read about. Pulled the separator and drained the fuel, but the bike is still acting hinky. So whats the next likely scenario? Am considering pulling the emission system apart and checking it. Im also intrigued by the possibility of pulling the whole vapor system out. Anyone have the procedure/pics for doing that.
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post #2 of 21 Old 01-07-2019, 11:22 AM
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If you do remove it, be certain to cap the vacuum nipple to the carb and the Elbow ahead of the battery that goes into the clean side of the air box!

pdwestman
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post #3 of 21 Old 01-07-2019, 01:55 PM Thread Starter
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I will! Before I go into surgery, anything else beside fuel in the separator that could cause those symptoms?
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post #4 of 21 Old 01-07-2019, 04:30 PM
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Over-filling the fuel tank was the immediate last thing done prior to malfunction, so I would not suspect any other reason.

Kawasaki once showed using an aquarium aerator to purge the charcoal canister of raw fuel & excess fumes. As in very low pressure air flow.
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pdwestman
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post #5 of 21 Old 01-07-2019, 04:37 PM Thread Starter
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Thanks. Don't really like the idea of leaving gas behind, so the de-Cali modification appeals to me.
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post #6 of 21 Old 01-07-2019, 04:55 PM
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Dis-connect all 3 hoses from the charcoal can. Connect low pressure air to the Blue air Inlet nipple and gently purge the canister for an hour or two.

pdwestman
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post #7 of 21 Old 01-07-2019, 05:14 PM
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Quote:
Originally Posted by rcecconi View Post
Thanks. Don't really like the idea of leaving gas behind, so the de-Cali modification appeals to me.
You will need a High Quality rubber cap to seal the nipple (which does not go to the fuel cap nipple) on the back of the fuel tank to capture the full tank volume. I can't determine which nipple color, Red or Blue? (Fuel cap must be Vented.)

pdwestman
Modify at "YOUR OWN RISK"!

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post #8 of 21 Old 01-08-2019, 03:59 PM Thread Starter
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Well, I performed the Cal-ectomy today and it didn't change anything. Capped off the red from the tank (blue is the cap vent) and the white "T" to the carburetor, but no joy. Wondering if the fuel cap ventilation might be the culprit. Don't know what else it could be. What have you heard/seen?
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post #9 of 21 Old 01-08-2019, 05:02 PM
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Try riding it with the gas cap open. If it is better then the umbrella seals are the issue. Could be they got full of fuel and the fuel hasn't evaporated yet. Or maybe it has and left an ethanol residue behind.

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post #10 of 21 Old 01-08-2019, 05:14 PM Thread Starter
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Thanks. I inspected them (umbrella seals) and they were wet, but not sticking. Should they be dry? Ran with the gas cap open and that didn't change anything. Also notice that in the garage holding the throttle at around 4K it would cycle up and down. I added choke and it stabilized. Think it could be a sticky choke?
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