When I opened my garage this morning I was greeted by the smell of gas
and on further inspection I found it was the KLX which had spewed it's
tankfull onto the floor!

I tracked it down to a split fuel line, and it happened because the
fuel tank was resting on the upper hose leading into the petcock, and
had worn through it.

What a lousy design. The fitting from the petcock is pointing up, and
there's very little space between the tank and the fitting.

Also, there's no extra length in the hose, so I ran a new one in a
coiled loop with lots of spare, and mounted the petcock so it's
actually sitting outside the mounting bracket, so the tank and hose
won't foul again. Was not easy to bolt there but it worked.

This shot is not great but it shows where the tank and hose met...



So, how much space is there on yours, or have you had to deal with this already?

Mike

 

Looks like this could be an issue only on the newer bikes (09 and on.)
There is plenty of room for hoses on the 07. The 09 does have a slightly larger tank.

Here's a shot of my 07 with an inline filter I fitted.

 

Thanks for the post, that reminds me I need to get some fuel line in preparation for my Oregon trip next week.

 

Will have to check mine now. Thanks for posting.

 

The 90deg nipple on the on/off switch can be turned down by hand giving you some room. I had to replace mine, tore it when I did the big bore.