2004 KLR-650: Draining the Carburetor Bowl

Warning

I am not a mechanic or a representative of Kawasaki or anything else official. This page is only my notes on doing this procedure myself. Although I believe what I have documented here is correct, I make no promises and you do this at your own risk.

Objective

Water and debris can build up in your carburetor, after long storage or riding in dirty or wet conditions. There is a drain that allows you to bleed such contaminated gas out of the bowl. My service manual suggests doing this every 5000 km or after a winter’s storage. Draining the carb is also good practice before winter storage to avoid having gelled gas varnish the inside of the carburetor.

Tools Required

  • Large Phillips screwdriver.
  • 3mm hex wrench.
  • 1 metre of gas line hose.
  • Small glass or plastic container to receive drained gas.

Potential Difficulties

  • Drained gas is toxic and flammable — be careful.

Procedure

Locate the carburetor, on the right side of the bike just under where your knee would be.
Inspect the carb closely. At the bottom is a small drain nipple, and a small drain screw.
Connect a short length of gas line hose to the drain nipple.

And run the house into a container on the ground.

In this photo, the end of the hose wouldn’t stay in the container — it kept wanting to curl up. So I just ran it through the hole in the handle of a pair of scissors, and that kept it in place in the container.

Loosen the drain screw about two turns. It uses a 3mm hex wrench.
Let the gas drain for a few seconds, until any apparent water or debris stops, then close the drain screw firmly.

Congratulations, you are done. You may find the bike a bit harder to start next time, since the carb bowl is empty.


2 Comments

  1. I couldn’t loose the screw, it is rusted and won’t come out, what could I do to remove it?

    • A few comments.
      – Consider getting help.
      – The screw is going to have to be replaced; so do this when your fastener supply store is open. Replace with a good-quality stainless steel screw.
      – Spray some penetrating oil such as “Liquid Wrench” onto the screw, and wait the recommended time.
      – Try a longer hex-key to get more leverage. A hex-key bit mounted in a socket wrench handle is a lot of leverage. Try that.
      – If the hex hole is stripped so that you can’t actually get a good grip on it with the hex wrench, as a last resort before giving up and getting professional help, consider buying a set of “screw extractors” – these are tapered, reverse-threaded tools. You drill into a stuck screw, then turn the screw remover into the hole with a wrench.

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