rear brake line

[Bill]

I pulled the petcock and dumped the old gas. The gas was Kawasaki green. The tube on the petcock looked like it had been shrink wrapped with burnt, green plastic. If that same gunk is inside the tank, I don't know if any reasonable amount of persuasion will free the locking mechanism on the gas cap. The tank is currently hanging upside down with a half gallon of mineral spirits inside. The mineral spirits had no effect on the gunked-up petcock, but I have to try. I'll post an update tomorrow. Thanks to Jeff for reminding me that I used to balance the carbs on my CB750 with a small bottle of gas hanging from the handlebars. Along with the battery out of the 'soccer mom' van, I got Humpty Dumpty running today. An overdose of Seafoam seemed to do the trick on the carb. It idles with the choke off. It has a slight stumble accelerating through 1500-1800 rpm. That might just be the Seafoam overdose. I'm letting the carb sit tonight with the Seafoam/gas mix. I'll run fresh gas through it tomorrow. I'm looking for a tank/cap (with key)/petcock combo. I've searched ebay. Petcocks run from $44.76 to $69.99, plus shipping. I can get a new one in the same price range. All of the tanks are beat-up, and don't include the cap and/or key and/or petcock. Unless someone on the list has something to offer, I'm thinking about going with a IMS tank. The KLR in question is a California model A15. I'm not too concerned about maintaining the stock emissions control system, as I'm currently in Oregon (and I gutted most of that crap when I first bought the bike). I'm sure someone on this list has installed an IMS tank on a Cali bike. Any suggestions? BTW, I'm also missing both side covers. I apparently didn't collect all of Humpty Dumpty's pieces from the evil disassembler. Anyone know of some A15 style, Army green, side covers for sale? I might be willing to consider other colors, specially if I go with the IMS tank and the price is right. TIA, Bill A15

[Jeff Khoury]

If you haven't completely given up on cleaning your old tank, instead of Mineral Spirits, try naptha or acetone to clean. In my experience, mineral spirits doesn't even touch the varnish. Don't mix them or smoke in the area! Then possibly some penetrating oil to lube the latch??? Cleaning the inside of the tank, I usually use several short lengths of chain or some washed pea gravel, then pour in some naptha (available at hardware stores). Then I have a friend help me shake and roll the tank for several minutes to scour off all the varnish. After fishing out the chain or shaking out all the gravel, you should have a clean, shiny tank. Of course whatever you use will probably destroy the petcock screen, so either remove it beforehand or buy a replacement. -Jeff Khoury

----- Original Message ----- From: "Bill" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Friday, November 20, 2009 10:35:03 PM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] gas cap stuck (part 2) I pulled the petcock and dumped the old gas. The gas was Kawasaki green. The tube on the petcock looked like it had been shrink wrapped with burnt, green plastic. If that same gunk is inside the tank, I don't know if any reasonable amount of persuasion will free the locking mechanism on the gas cap. The tank is currently hanging upside down with a half gallon of mineral spirits inside. The mineral spirits had no effect on the gunked-up petcock, but I have to try. I'll post an update tomorrow. Thanks to Jeff for reminding me that I used to balance the carbs on my CB750 with a small bottle of gas hanging from the handlebars. Along with the battery out of the 'soccer mom' van, I got Humpty Dumpty running today. An overdose of Seafoam seemed to do the trick on the carb. It idles with the choke off. It has a slight stumble accelerating through 1500-1800 rpm. That might just be the Seafoam overdose. I'm letting the carb sit tonight with the Seafoam/gas mix. I'll run fresh gas through it tomorrow. I'm looking for a tank/cap (with key)/petcock combo. I've searched ebay. Petcocks run from $44.76 to $69.99, plus shipping. I can get a new one in the same price range. All of the tanks are beat-up, and don't include the cap and/or key and/or petcock. Unless someone on the list has something to offer, I'm thinking about going with a IMS tank. The KLR in question is a California model A15. I'm not too concerned about maintaining the stock emissions control system, as I'm currently in Oregon (and I gutted most of that crap when I first bought the bike). I'm sure someone on this list has installed an IMS tank on a Cali bike. Any suggestions? BTW, I'm also missing both side covers. I apparently didn't collect all of Humpty Dumpty's pieces from the evil disassembler. Anyone know of some A15 style, Army green, side covers for sale? I might be willing to consider other colors, specially if I go with the IMS tank and the price is right. TIA, Bill A15 [Non-text portions of this message have been removed]

[transalp1@mindspring.com]

It may have been tried already. But, how about taking plastic, shot-filled mallet and giving the gas cap a firm smack or two? Not so hard as to dent the tank. Yet, get it attention. THUNK! Worth a try. -eddie -----Original Message-----

>From: Bill >Sent: Nov 21, 2009 1:35 AM >To: DSN_KLR650@yahoogroups.com >Subject: [DSN_KLR650] gas cap stuck (part 2) > >I pulled the petcock and dumped the old gas. The gas was Kawasaki green. The tube on the petcock looked like it had been shrink wrapped with burnt, green plastic. If that same gunk is inside the tank, I don't know if any reasonable amount of persuasion will free the locking mechanism on the gas cap. The tank is currently hanging upside down with a half gallon of mineral spirits inside. The mineral spirits had no effect on the gunked-up petcock, but I have to try. I'll post an update tomorrow. > >Thanks to Jeff for reminding me that I used to balance the carbs on my CB750 with a small bottle of gas hanging from the handlebars. Along with the battery out of the 'soccer mom' van, I got Humpty Dumpty running today. An overdose of Seafoam seemed to do the trick on the carb. It idles with the choke off. It has a slight stumble accelerating through 1500-1800 rpm. That might just be the Seafoam overdose. I'm letting the carb sit tonight with the Seafoam/gas mix. I'll run fresh gas through it tomorrow. > >I'm looking for a tank/cap (with key)/petcock combo. I've searched ebay. Petcocks run from $44.76 to $69.99, plus shipping. I can get a new one in the same price range. All of the tanks are beat-up, and don't include the cap and/or key and/or petcock. Unless someone on the list has something to offer, I'm thinking about going with a IMS tank. The KLR in question is a California model A15. I'm not too concerned about maintaining the stock emissions control system, as I'm currently in Oregon (and I gutted most of that crap when I first bought the bike). I'm sure someone on this list has installed an IMS tank on a Cali bike. Any suggestions? > >BTW, I'm also missing both side covers. I apparently didn't collect all of Humpty Dumpty's pieces from the evil disassembler. Anyone know of some A15 style, Army green, side covers for sale? I might be willing to consider other colors, specially if I go with the IMS tank and the price is right. >TIA, >Bill >A15 > > > >------------------------------------ > >List sponsored by Dual Sport News at: www.dualsportnews.com >List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html >Member Map at: http://www.frappr.com/dsnklr650Yahoo! Groups Links > > >

[Jeff Khoury]

Oh, and I forgot... The stumble as you come off closed throttle is most likely still some clogging in the transition jets. If you look in the side of the carb that fits to the intake boot, you will see tiny holes drilled in the bottom of the throat, just below the butterfly. These are the pilot and transition holes. There is one that is normally uncovered when the bike is idling, and you can normally see this one. The others (usually 2-3 additional holes) are uncovered as you begin to open the throttle. These provide a small amount of additional fuel to "fill in" during the transition from idle to the needle/main jets. The way to clean them is to prop the butterfly open with the handle of a small screwdriver (the softer the better), then take a brass wire brush strand and poke it down all those tiny holes. Spray the whole thing out with K&W carb cleaner and your stumble should be gone. While you're that far in, take off the top of the carb, clean the needle and run a pipe cleaner down where the needle normally sits. Re-assemble and you're off to the races. -Jeff Khoury Astatic Solutions, LLC.

----- Original Message ----- From: "Bill" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Friday, November 20, 2009 10:35:03 PM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] gas cap stuck (part 2) I pulled the petcock and dumped the old gas. The gas was Kawasaki green. The tube on the petcock looked like it had been shrink wrapped with burnt, green plastic. If that same gunk is inside the tank, I don't know if any reasonable amount of persuasion will free the locking mechanism on the gas cap. The tank is currently hanging upside down with a half gallon of mineral spirits inside. The mineral spirits had no effect on the gunked-up petcock, but I have to try. I'll post an update tomorrow. Thanks to Jeff for reminding me that I used to balance the carbs on my CB750 with a small bottle of gas hanging from the handlebars. Along with the battery out of the 'soccer mom' van, I got Humpty Dumpty running today. An overdose of Seafoam seemed to do the trick on the carb. It idles with the choke off. It has a slight stumble accelerating through 1500-1800 rpm. That might just be the Seafoam overdose. I'm letting the carb sit tonight with the Seafoam/gas mix. I'll run fresh gas through it tomorrow. I'm looking for a tank/cap (with key)/petcock combo. I've searched ebay. Petcocks run from $44.76 to $69.99, plus shipping. I can get a new one in the same price range. All of the tanks are beat-up, and don't include the cap and/or key and/or petcock. Unless someone on the list has something to offer, I'm thinking about going with a IMS tank. The KLR in question is a California model A15. I'm not too concerned about maintaining the stock emissions control system, as I'm currently in Oregon (and I gutted most of that crap when I first bought the bike). I'm sure someone on this list has installed an IMS tank on a Cali bike. Any suggestions? BTW, I'm also missing both side covers. I apparently didn't collect all of Humpty Dumpty's pieces from the evil disassembler. Anyone know of some A15 style, Army green, side covers for sale? I might be willing to consider other colors, specially if I go with the IMS tank and the price is right. TIA, Bill A15 [Non-text portions of this message have been removed]

[Chris Long]

I'm looking for the difference between a 2008 and a 2009.

On Sat, Nov 21, 2009 at 1:43 PM, Jeff Khoury wrote: The braking system received a major upgrade for 08. New calipers, petaled rotors, etc. -Jeff Khoury Astatic Solutions, LLC. ----- Original Message ----- From: "Chris Long" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Saturday, November 21, 2009 12:40:42 PM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Rear brake line I was looking at some pictures and I noticed that the rear brake line is coming out the back of the caliper on the 2009. It comes out the front of my 2008. I didn't know there were anything but cosmetic changes between the two. Is there a different caliper, rear brake line, disc, etc. Or is the banjo bolt just turned around? -- Chris Long Chris.M.Long@...

-- Chris Long Chris.M.Long@...