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Discussion Starter #1 (Edited)
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.
 

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https://www.souperdoo.com/stuff that i think about/why-won-t-that-damn-pivot-bolt-come-out-or-two-very-important-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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Discussion Starter #3
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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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:
 

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Discussion Starter #5 (Edited)
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.
 

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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.
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!
 

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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.
 

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Discussion Starter #8
Awesome...i will just plug that sucka...that was easy... I thought I needed it. Thanks...
 

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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.
Pbk16gt,
IMO, YOU have a bigger problem than your forward air box drain hose!

In your second pic, the large crankcase Vent Hose is Not Shown to be attached to the large Nipple of the clean side of the air box, above your remote preload adjuster. The engine will suck Dirty Air thru there also!

Is that nipple plugged? If plugged is the bike using a K&N crankcase vent filter for some silly reason?
 

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The small black hose near the shock absorber bolt in pic #2 should be from the rear of the fuel tank. It is a fuel tank vent. do NOT plug it.
 

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Discussion Starter #14
Yes, I had read that thread, and another one about the hose. It is the hose that is in the pics below, correct.
Pbk16gt,
IMO, YOU have a bigger problem than your forward air box drain hose!

You my man, are my hero! I have found the large diameter clear hose and plugged it. I also found the missing end of the crankcase vent hose and plugged it into the air box. Also, embarrassing...i unplugged the fuel tank vent hose, lol. I am gonna assume that between the crankcase hose not being connected and the clean side (clear hose) not being plugged, is why it was sputtering after riding through some sand. It seems to,run good, and lucky for me , I ride like a old man, in sand (I am old as dirt). Thank you very much, for your help, as I was lost, and now I am found!
 

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The sputtering after riding in sand, working the engine hard & at low speeds could have been caused be the exhaust pipe over-heating the gasoline in the carburetor float bowl. This makes the engine run rich, sort of like one pulled the cold start enrichener on.

A few people have used exhaust pipe heat wrap tape under the heat shield or made an extended heat shield or both.
 

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Discussion Starter #16
The sputtering after riding in sand, working the engine hard & at low speeds could have been caused be the exhaust pipe over-heating the gasoline in the carburetor float bowl. This makes the engine run rich, sort of like one pulled the cold start enrichener on.

A few people have used exhaust pipe heat wrap tape under the heat shield or made an extended heat shield or both.
So, is this common, on the KLR? Cause, I would hate to think how it would be if I was really messing around in the sand. I won't need to look at 60/40 dirt/road tires as, this bike won't cut it for that type of playing. Not that it is a bad bike, just not designed for aggressive dirt riding.
 

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Does it sound like my description fits your symptoms from posting #1? Cleared up after you got out of the sand & sped up?
 

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The description and the possible cure was previously supplied to us by another member.

GoMotor deserves all the credit if this heat shielding tip/modification helps anyone.
 
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