Kawasaki KLR-650 Microfiche View

The picture below is from the microfiche taken from the official Kawasaki KLR-650 parts fiche. It shows all of the equipment that is part of the California model of the KLR-650. You do not need to remove all of this stuff, just some of it. Please refer to this picture at all times while doing the removals. All numbers in brackets like this [92059A] refer to the part number on the diagram.

1. Get your bike into a nice comfortable position. Gather some tools. Get a beer. Turn on some tunes.
2. Remove the side panels and seat

3. Remove the radiator shrouds.

4. Remove the gas tank.

Besides the two bolts at the rear there are a total of 4 hoses to remove.

1. Charcoal Canister Removal [16164, 11045, 130A, 92072, 14024, 130]

Shown below is the charcoal canister, it’s bracket, cover, and mounting bolts. Far left is the actual charcoal canister. Center is the cover that bolts over the canister to protect it. On the right is the bracket that holds it all to the bike. At the top center is the rubber strap that holds the canister to the bracket. Top right is the helmet holder. I removed it also as I do not use it and it just gets in the way. It is not part of the de-ca process.

1. Look at the left rear of your KLR - you will see the charcoal canister and all of it's associated plumbing.

2. Using a pair of pliers cut both of the hoses that exit from the charcoal canister. Leave in place.

3. Using a variety of hand tools, remove the cover, canister, it's bracket, and any other stuff in the general area that look like it belongs to the charcoal canister or it's mount. Put this in a box for saving. In the picture below you can see the left rear section of the KLR. All of the hardware for the charcoal canister and helmet lock has been removed. This is what it looks like.

1. Fuel/Vapor Separator [16165, 92072A, 92037 (4 pieces)]

In the pictures below you see the fuel separator (fuel hoses cut off), along with the strap that holds it in place. The last piece is the bracket, which I have removed from the bike by cutting it off with a dremel tool.

1. Look at the left side of your KLR just to the rear of the plastic cover that contains the side stand wire /cable connection. Just to the rear of that you will see a small, black, circular device [16165] about the size of a large fuel filter. This is the fuel/vapor separator.

2. Remove the rubber strap that holds the separator in place [92072A] and pull the separator as far out from the bike as the plumbing will allow. You will notice that it contains 4 hose attachments.
3. Remove or cut off all four hose attachments and put all 4 fasteners (92037) in box.
4. Place the fuel/vapor separator in the box with all of the other removed parts. You no longer need this.
5. If you wish to remove the black bracket [11045A] that held the separator in place I recommend you do one of the following:

1. For an easy fix, simply bend the bracket back and forth (left to right) until the metal fatigues and the bracket is free. In the picture below look just to the left of the silver frame member and you will see the plastic cover for the side stand cable. Just to the right of that you can see where the bracket has been cut off.

2. For a better fix, remove the plastic cover over the side stand cable cover, use a dremel tool and cut along a vertical line that will remove all of the bracket except for the small piece which is contained within the side stand switch support. Put the cover to the side stand switch back on.

1. Plumbing Updates

1. Fuel Separator -> Charcoal Canister - There is a single thin hose [92059C] that runs from the fuel/vapor separator back to where the charcoal canister lived. It ran along the left side of the bike behind the left side cover. Remove this piece of plumbing line entirely. Place in box of saved parts. In the picture above this hose is already removed. It ran along the left side of the rear subframe. You can see a piece of black plastic with holes in it. The hose originally ran along the top of this to the rear of the bike where the canister used to sit.
2. Air Box -> Charcoal Canister - A much thicker piece of hose [920598] runs from the front of the airbox to where the charcoal canister used to be. It too runs along the left side of the bike behind where the left side body panel would be. Cut this tubing shorter and plug the end. I plugged mine with an end cap from a Bic pen. You can also put a piece of filter over this and fasten the filter on if you wish to filter and not plug. Your choice. In the picture above you can see the big hose as it emerges just to the rear of the battery and goes towards the back of the bike. I cut my hose shorter and then inserted a pen cap in the end to block it. The hose can been seen laying on top of the black piece of plastic with holes in it.
3. Fuel Separator to Gas Tank Vents - At the rear of the gas tank (now removed) there are two pieces of hose. One has a red stripe [92059A] and the other a blue [92059E]. With the tank removed these pieces are now sitting in the bike and poke up through a round metal piece on the frame. Pull both hoses out from the bike all the way. Using a pair of pliers to cut these pieces until they are about 12-16" long. Put them back into the bike with the top end of both hoses being in exactly the same location as before and the lower ends dangling down near the shock. These will now act as tank vents.
4. Gas Tank Vacuum Line -> Carburetor - When you removed the gas tank from the bike there were two pieces of rubber hose that were connected near the fuel petcock. One is small and one is large. The larger one is the actual fuel line that allows fuel to flow from the tank to the carburetor. Do nothing to this one. The smaller of the lines is the vacuum line. What this does is to create a vacuum from the carburetor to the diaphragm in the fuel petcock that allows fuel to flow. If this line were not in place no fuel would flow. If you examine the smaller piece of tubing starting at the end where it connects to the tank (if it were in place) you will notice there is a T fitting about 6-10" along the line. Out of this T fitting one piece of tubing goes to the top front of the carburetor. The other goes to where the fuel/vapor separator used to be [920590]. You will want to eliminate the T fitting. All that you need is a single piece of hose that goes from the gas tank end directly to the top of the carburetor. Nothing else is needed. Remove all of the existing plumbing and replace it with one of the already salvaged pieces of same size hose and run this from the carburetor to where the hose used to sit near the gas tank petcock area. Put the other pieces in the box to save.

1. Put the gas tank back on the bike. Connect the two vent hoses at the rear of the tank. Connect the two hoses down at the petcock.
2. Replace radiator shrouds, seat, and side panels.
3. Turn gas petcock on
4. Go Ride!