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Discussion Starter #1
Trying to figure out the leak from my tank/petcock/hose but not sure if the petcock on the bike is oem or not (I bought the bike used and somewhat beaten up). Before I go buying new gaskets/rebuild kits etc I want to make sure I'm buying the right stuff.

Somehow the petcock on my C model doesn't look quite right.

Many thanks and high fives from Montreal
 

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These pics are from the repair manual untIL year 2013. I hope they will serve you. My bike is 2016. The first 3 are of the manual and the last 2 of my bike.
 

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Discussion Starter #3
Thanks man appreciate it. Do you think that's the also the OEM petcock for the C model, year 2000? It definitely is different to the one I have on my ride - mine has a PRI (prime) setting but no RES
 

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Kawasaki provides a pretty good web site where there is access to the parts manual. One of the values of a parts manual is that it will show exploded views of the entire bike. Here's the "sign in" page for this: https://www.kawasaki.com/myaccount/signin

For instance, the attached is what it shows for my 2007 Fuel Tank.

I can also go to Google Images and search for the part number that Kawasaki lists on the above web site and that will usually generate a lot of camera quality pictures. In this case the Part Number is: 51023-0003.

For example this link has a whole lot of excellent close-up shots of the "Kawasaki 1987-2016 KLR 650 Fuel Tap Shut Off Valve 51023-0003" https://www.louispowersportsonline.com/products/kawasaki-1987-2016-klr-650-tengai-klr650-new-edition-camo-fuel-tap-shut-off-valve-51023-0003-new-oem
 

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It might be best if you were to post a picture of your petcock.

Most of us are in the US and the "C" model was never sold here, so is quite rare to us. Further, our usual sources of info, the fiches and manuals, don't cover the "C" model.

If we see your petcock we may be able to give you some advice on fixing or replacing it.

The KLR650C has a petcock that is backwards from the "A" and "E" models in that the outlet is forward of the petcock rather than aft, and the primary tube is probably (should be) shorter than the "A" and "E" both because the petcock is farther back in the tank where there is less vertical room and because the tank is about 2/3 the size of the "A" and "E" tank.

A Yamaha Raptor 660 petcock might be a replacement solution, as its primary tube is quite short. I don't know if hose routing would be a real problem, though.

I will go look at an "E" petcock and see if the hose can be easily switched.

Here's a picture of the "E" petcock vs the Raptor.

 

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Yeah, the "A" and "E" petcock is designed to be manufactured with the outlet on either the right side or the left side. It would be possible to modify one so that the outlet was on the forward, or left, side. The as-cast part for the left side is slightly under-size, almost perfect for reaming. The primary tube would need to be shortened.

The outlet elbow in these petcocks is a wring-fit and I believe a hardening sealer is used to secure it. They aren't hard to remove without any damage; in fact they some times fall out on their own.

This would be a project of last resort, preserving originality and all that. High probability that the right-side outlet would work with a bit longer fuel line, unless it would get in the way of something I can't think of. Might just be awkward.

It would require a good drill press to drill a port on the left side and ream the opening to 5/16". The outlet elbow would then be installed on the left side with a hardening sealer and a 5/16" plug would be put in the right side. This is probably a job that would take no more than an hour.

If you're ever interested in doing this I can take pictures showing the requirements.
 
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