So I went into Napa Auto Parts today to try to grab a set of various vacuum caps and they only offered some very small stuff. The behind the counter box of assortment were all very small and the mixed kit they sold on the shelves also seemed a bit small, so here's my question:

Does anyone have the actual sizes of the correct caps to use when removing the smog system?
(Also, the only thing that comes off is the three-way hose [all three parts] that comes off the front of the cylinder?)

I might end up having to order some online, seeing as I live in the boonies for autoparts stores, so I want to get close. And I am trying to avoid getting all the hoses off till I have the actual caps, which makes the measuring part hard. Thanks for any input guys. (And KC)

 

I bought a box of assorted caps at a local Napa's. There seems to be all the proper sizes there, and if anything, they're rubber, so you could always find the closest one that's just a tad bit smaller, then stretch the cap and put a hose clamp over it

 

I just did the mod to mine yesterday. The caps were available at both Advance Auto Parts and O'reillys. I took the smog mess with me and we pick out from a various assortment they had on hand and the caps fit perfectly. Teh one problem I did have was with opening up the crankcase breather opening. I have a new 07 and you cannot just take a drill bit and start turning it and expect it to cut through the plastic. Ended up buying a torch and putting a heated drill bit through the opening, only way it can be done. After completion, there was a world of difference in the amount of heat I had been feeling coming from the engine. It is running great, took it for a 25 mile ride at sunrise last night and ran like a dream. Anyone who has not taken this crap off the bike is making a big mistake. I also installed a UNI Filter and Iridium Plug. My first mods went very smoothly except for having to purchase the torch but it was necessary to open up the airflow to the crankcase. The caps are the only way to go and there are plenty available at auto parts stores. I do not use NAPA that much myself but the other stores I mentioned had a large assortment. Good luck and get that mess off the KLX. It is a first to do mod as after 20 miles my exhaust header pipe was turning blue due to the heat being created from the smog crap. Next to come is my Two Brothers, carb rejetting, snorkel is on order and new gearing I have not decided on just yet.

 

I'm going to wait till I get an aftermarket exhaust system to remove the smog crap.

So long as that Catalytic convertor is still on your bike, you may as well make use of it, help the environment, all that good stuff.