Vacuum Fuel Tap Changed into Water Trap Manual Fuel Tap - 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 19 Old 08-16-2019, 09:54 PM Thread Starter
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Join Date: Jul 2019
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Vacuum Fuel Tap Changed into Water Trap Manual Fuel Tap

If your tap has a "PRI" this mod won't work for you. If your fuel tap has an "OFF" then it will

If you don't want the water trap, plug off the vacuum port with a chunk of hose n a bolt or, drill and tap the vacuum port to a 4 mm screw, put a gasket washer on the screw and use one of the diaphragms as a gasket and you're done.

So .... to make a water trap - Here it is (Imagine that black hose hanging down is clear.)



How i got to that point is I took off the back of the fuel tap (after removing the fuel tank)
Then...



Drilled off the top ring and separated the pieces of the diaphragm

Then



Very important - the arrow points to a round dot, that is the one way valve that is under the vacuum spigot. Use a wrench and take that out. Blow from diaphragm side to blow it out. While the spigot is out, drill a hole into the passage the spigot screws into. There is already a divot exactly where you want to drill. only drill through the first side of the passage, about 3/16" deep.

Then Take One of the two diaphragms and cut a passage to the bottom leaving the sealing surface alone. (doesn't need to be pretty, and you have a spare Gasket as the tap had two diaphragms)

Be sure to line up the slot you cut with the hole you drilled

re assemble except turn the spigot down, use the stock screws you took out. Leave the vented spacer plate and the spring on the bench. and make sure you're using the one gasket you cut with the slot lined up with the hole you drilled.

Be sure to plug off the vacuum line that no longer has a home ! ! ! !

Spring clamps are a great idea for the hose. Self tightening. And a clear hose is a nice touch. I'll get mine soon ish

and wala


You're DOne ( think Clear Hose There LOL)

Maybe i'm not the first one to post this idea, but, here it is anyhow

P.S Instead of the hose hanging down you could drill and tap the spigot to a 4 mm bolt and just seal it off, With a Oversize bit and drill , cut a small landing for a small o ring n done.
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Last edited by JdgDReDD; 08-17-2019 at 06:56 AM.
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post #2 of 19 Old 08-16-2019, 10:21 PM
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Location: Lander, Wyoming
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Well, the water trap is a fresh idea.

But the forward corners of the fuel tank can hold a Lot more water than your trap can hold!
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #3 of 19 Old 08-16-2019, 10:53 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Well, the water trap is a fresh idea.

But the forward corners of the fuel tank can hold a Lot more water than your trap can hold!
So the trap is a Good indicator when its time to check the tank ! and keeps water out of the carb until you do.

A person could even put a A/M fuel valve, (An in line 180 degree lawn mower fuel valve would work nicely) instead of a plug in the water drain (clear hose instead of black), and then route an additional hose from the valve down to where the other drain hoses go by the swing arm, then you could just turn the valve to let the water out. This is the way i'm going

OR

Leave it sideways and just plug it off ,

A person could even put a A/M fuel valve, (An in line 180 degree lawn mower fuel valve would work nicely) instead of a plug in the water drain, and then route an additional hose from the valve down to where the other drain hoses go by the swing arm, then you could just turn the valve to let the water out. this is the way i'm going

The water trap idea came from my snowmobile knowledge

I also have a lot of experience tuning personal watercraft. (sea doo's n the like)

In the end it's still a mod that costs nothing but time. No KIts, couple clamps and a chunk of hose to get away from the vacuum tap

and if you want a drain able water trap, wala, you got it. And you have an extra gasket providing you don't ruin one while cutting it.

Last edited by JdgDReDD; 08-17-2019 at 09:50 AM.
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post #4 of 19 Old 08-17-2019, 09:58 AM
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Anyone besides me remember in-line fuel filters with transparent bowls on the underside, such bowls removable to drain water and any visible crud?

Wonder why such components don't appear to be in use (at least, much) today?

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #5 of 19 Old 08-17-2019, 10:05 AM
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Due to the shape of the fuel tank on both sides, there is probably enough volume for about 3-4 ounces of water to collect on each side of the tank. By the time one might find water in the petcock water trap, the fuel tank might be rusting thru?

Best to use a flashlight occasionally while the fuel level is well down on reserve to look inside the forward corners for contaminates/water and siphon it out before it becomes a problem.

With the occasional or full time use of gasohol fuels (which absorbs & then suspends any water) while on longer road trips, I find fewer bikes with water puddles in the bottom of their fuel tanks currently, than I did in the 70's & 80's. But I still hate ethanol laced fuels for its storage degradation.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #6 of 19 Old 08-17-2019, 10:17 AM Thread Starter
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I do

they are common use items in my area to this day

Quote:
Originally Posted by Damocles View Post
Anyone besides me remember in-line fuel filters with transparent bowls on the underside, such bowls removable to drain water and any visible crud?

Wonder why such components don't appear to be in use (at least, much) today?
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post #7 of 19 Old 08-17-2019, 10:20 AM Thread Starter
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all our fuels up here in central canada are labeled "may contain up to 15% MTBE" If memory serves. and methanol warnings. There is a huge ethanol refinery on the edge of town. LOL

Thats why i like cheaper fuel brands, less additives . The big dogs put all their fancy crap in it.

Quote:
Originally Posted by pdwestman View Post
Due to the shape of the fuel tank on both sides, there is probably enough volume for about 3-4 ounces of water to collect on each side of the tank. By the time one might find water in the petcock water trap, the fuel tank might be rusting thru?

Best to use a flashlight occasionally while the fuel level is well down on reserve to look inside the forward corners for contaminates/water and siphon it out before it becomes a problem.

With the occasional or full time use of gasohol fuels (which absorbs & then suspends any water) while on longer road trips, I find fewer bikes with water puddles in the bottom of their fuel tanks currently, than I did in the 70's & 80's. But I still hate ethanol laced fuels for its storage degradation.
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post #8 of 19 Old 08-17-2019, 10:30 AM
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Location: Lander, Wyoming
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Is MTBE still legal to use in Canada?

I think it was outlawed in the USA in the '90s & replaced by ethanol as an easy octane booster. Then the 'enviromentalists' suggested we needed to use more ethanol as a 'renewable' fuel source to stretch our petroleum reserves, yeah right! (Law of diminishing returns, imo.)

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #9 of 19 Old 08-17-2019, 11:29 AM Thread Starter
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Can't say i've paid attention to the warnings on the pump in a long time. I'll look next time i go . all the fuel up here has ethanol or methanol.



Quote:
Originally Posted by pdwestman View Post
Is MTBE still legal to use in Canada?

I think it was outlawed in the USA in the '90s & replaced by ethanol as an easy octane booster. Then the 'enviromentalists' suggested we needed to use more ethanol as a 'renewable' fuel source to stretch our petroleum reserves, yeah right! (Law of diminishing returns, imo.)
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post #10 of 19 Old 08-17-2019, 12:42 PM Thread Starter
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finished version



i shortened the line a bit after the photo was taken

and now you can easily fill your camp stove or give a buddy some fuel if he ran out
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Last edited by JdgDReDD; 08-18-2019 at 06:15 AM.
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