Gen2 evaporative emission control system - 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 31 Old 02-22-2019, 06:14 PM Thread Starter
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Gen2 evaporative emission control system

Okay, I recently bought this 2015. It has Tusk pannier racks on it and i went to pull the left panel. Something was in the way that i am unfamiliar with. Consulted the Clymer and it looks like I got Californicated here. Thing is, here in IA, a guy has a strong desire to rip any EPA out of his equipment. Our diesels are deleted and run straight pipes, cant imagine not messing with this on the KLR.
Of course I would appreciate any advise so I dont cause anything to come back and bite me in the arse.

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post #2 of 31 Old 02-22-2019, 06:17 PM Thread Starter
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I need to do a little drinkin' on this one.

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post #3 of 31 Old 02-22-2019, 07:39 PM
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The GREEN fitting goes into the Clean side of the air box! Gotta' plug that hole.
A longer hose to the BLUE nipple on the tank, from gas cap vent nipple down past shock spring.
A High Quality cap on the RED nipple on the tank. Otherwise you can't put the full 5.928 usable gallons into the tank.
A High Quality cap on the WHITE 'T' nipple or delete T. Still gotta' have vacuum to fuel tap.

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post #4 of 31 Old 02-22-2019, 08:18 PM Thread Starter
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So plug the green

Extend the blue down past the shock

Cap the red at the tank

Cap off or eliminate the T on the white.

So, do away with the canister as well as the liquid/vapor separator?

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post #5 of 31 Old 02-22-2019, 08:34 PM
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Iím curious, other than a bit of weight savings, what is gained by removing the canister and etc?

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 31 Old 02-22-2019, 08:51 PM Thread Starter
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Personally, not concerned with a weight savings. It's because I'd rather not pull pannier racks to remove the left side panel. I've read in other places that the panels come off fine with these racks in place but I suspect the folks posting aren't dealing with California emissions requirements.


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post #7 of 31 Old 02-22-2019, 09:05 PM
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Quote:
Originally Posted by dan filipi View Post
Iím curious, other than a bit of weight savings, what is gained by removing the canister and etc?
About 2-3 pints of fuel capacity & zero chance of over-filled 'Hot start/running' issues due to a flooded charcoal can.

I've had to Fast IDLE my 1988 Ford Ranger about 7 miles of road time due to over-filling the fuel tank, more than once.

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post #8 of 31 Old 02-22-2019, 09:05 PM Thread Starter
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Because every way I turn and cock it, just not getting past the canister.

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post #9 of 31 Old 02-23-2019, 07:22 AM
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Lol...I also got "Californicated" here in Florida.

I purchased my 2016 Camo Model new at my dealer in Brandon, Florida and didn't notice the california vapor recovery garbage for about a week. I purchased many new motorcycles. You're not expecting it; you're not looking for it; you don't know what to look for! My dealer was equally surprised, but they subsequently determined from momma kawi that all Camo models produced were Cali Models. So, at least for the 2016 model year, if you wanted a digi-camo model you'd get a cali model.

An additional "A" at the end of the model number on your sales order is the indicator that it's a Cali Bike as in KL650EGFA for my 2016 and KL650EJFA for your 2018.

I bought my 2016 in 12/2015 but it wasn't until this past October that I removed all the cali emissions crappola. Basically, what I'd learned early on is that it didn't help anything and it didn't hurt anything. So I grumbled a little, but just left it on and pretty much forgot about it. It wasn't until I got into some serious motor work last October that I found how much crap there really was to that system. Basically I pulled it all out to get it out of the way!

At the same time, I did the Air Induction System (AIS) Blockoff using the Eagle Mike Air Induction Blockoff Kit. More emissions stuff, the AIS draws fresh air (from inside the frame) into the exhaust header to help ignite unburned fuel. Mostly another doesn't hurt or help anything, except in the case of some aftermarket pipes that experience much more decel popping than the oe to the point of backfire. It actually made a noticable difference with the Yoshi I'd installed earlier in 2018. Something else to consider as you dig out all the unnecessary plumbing on the KLR650.

I chronicled my Vapor Recovery and AIS removal in a blog post. Have a look...

The Eagle Mike AIS Blockoff Kit is under $15:
https://www.eaglemike.com/Air-inject...ff-kit-AIS.htm

Here's the blog writeup:
http://kamoklr.blogspot.com/2018/10/...s-removal.html

Last edited by Bill10; 02-23-2019 at 07:26 AM.
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post #10 of 31 Old 02-23-2019, 07:36 AM Thread Starter
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I'll check that out, thanks!
The link just takes me to EM's page for the AIS blocking plate.



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