ez pull clutch

[keithwuenstel]

Ok, I'll try to keep this short but here's the scoop: I'm installing an IMS tank on my '00 650 and just for grins wanted to accrately measure the capacity since IMS states that they may vary in manufacture process. So I get the brainstorm to just measure how much water it takes to fill it. I reasoned water would be OK choice 'cause I have the bike in my basement for winter maintenence etc, didn't want the gas hazard and there's a good couple weeks for it to dry out. In any case, once I got it filled up to the petcock reserve tube it started leaking the water out of the petcock seam (or somewhere) but NOT the petcock to tank gasket area...good seal there. There were NO leaks from this petcock when it was on my stock tank so there lies the mystery to me. Does anyone have an answer for why it's leaking the water?

[J Fortner]

On 3/5/06, keithwuenstel wrote:

> > Ok, I'll try to keep this short but here's the scoop: I'm installing > an IMS tank on my '00 650 and just for grins wanted to accrately > measure the capacity since IMS states that they may vary in > manufacture process. So I get the brainstorm to just measure how much > water it takes to fill it. I reasoned water would be OK choice 'cause > I have the bike in my basement for winter maintenence etc, didn't want > the gas hazard and there's a good couple weeks for it to dry out. In > any case, once I got it filled up to the petcock reserve tube it > started leaking the water out of the petcock seam (or somewhere) but > NOT the petcock to tank gasket area...good seal there. There were NO > leaks from this petcock when it was on my stock tank so there lies the > mystery to me. Does anyone have an answer for why it's leaking the water?

You need to take the stock OEM gasket out of the petcock and only use the IMS petcock gasket. The OEM gasket is recessed into the base of the petcock. These two gaskets together WILL leak. Been there done that. Jim [Non-text portions of this message have been removed]

[Andrus Chesley]

The OEM gasket is recessed into the base of the

> petcock. These two gaskets together WILL leak. Been there done that. > > Jim

Me too. '43 Andy in Jennings, La '00 KLR650 '02 R1150GSA '03 Chevy truck

[J Fortner]

On 3/6/06, Andrus Chesley wrote:

> > The OEM gasket is recessed into the base of the > > petcock. These two gaskets together WILL leak. Been there done that. > > > > Jim > > Me too.

Thanks Andy! Misery loves company. [Non-text portions of this message have been removed]

[keithwuenstel]

Thanks for all the advice. I removed the stock O ring and bolted it back on the tank. Since this issue has been discovered I figured I better continue to test the seal with water. I have the bolts tightened down good but still have a drip about every 10 seconds. This is frustrating and IMS is going to get some feedback from me on this. Most critical area of the installation and the instructions are just plain lame.

[Gavin Macfarlane]

Keith, I've stayed out of this so far, I bought an IMS in about April 2005, we had to file down the petcock seat on the tank two or three milimetres to get a flat seal. Quality control was rubbish. I had airfreighted it into Australia, so unfortunately returning it was way more than the tank was worth. BTW I bought a spare petcock so that I can swap tanks whenever I want without having to changeover petcocks keithwuenstel wrote:

> Thanks for all the advice. I removed the stock O ring and bolted it > back on the tank. Since this issue has been discovered I figured I > better continue to test the seal with water. I have the bolts > tightened down good but still have a drip about every 10 seconds. > This is frustrating and IMS is going to get some feedback from me on > this. Most critical area of the installation and the instructions are > just plain lame. >

-- Gavin Broadford Victoria Australia KLR650A18 DL650K6 Home of the DSN-KLR650 searchable archive at:- http://dsnklr650.gavinmac.com

[Denis Dimick]

I just installed my IMS tank last night, thanks Fred for getting it to me so quick, I found that I had to tighten down the bolts fairly tight. When I first put the petcock on, I tightened the bolts as tight as I thought they should be, then re-tightened them. After the second round of tightening, the petcock stopped leaking. HtH, Denis

On 3/7/06, Gavin Macfarlane wrote: > > Keith, > > I've stayed out of this so far, I bought an IMS in about April 2005, we > had to file down the petcock seat on the tank two or three milimetres to > get a flat seal. Quality control was rubbish. I had airfreighted it into > Australia, so unfortunately returning it was way more than the tank was > worth. > > BTW I bought a spare petcock so that I can swap tanks whenever I want > without having to changeover petcocks > > keithwuenstel wrote: > > Thanks for all the advice. I removed the stock O ring and bolted it > > back on the tank. Since this issue has been discovered I figured I > > better continue to test the seal with water. I have the bolts > > tightened down good but still have a drip about every 10 seconds. > > This is frustrating and IMS is going to get some feedback from me on > > this. Most critical area of the installation and the instructions are > > just plain lame. > > > -- > Gavin > > Broadford Victoria Australia > KLR650A18 > DL650K6 > > Home of the DSN-KLR650 searchable archive at:- > http://dsnklr650.gavinmac.com > > > > Archive Quicksearch at: > http://www.angelfire.com/ut/moab/klr650_data_search.html > 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/dsnklr650 > Yahoo! Groups Links > > > > > > > [Non-text portions of this message have been removed]

[Gavin Macfarlane]

Good oh Keith, IMS did send me some gaskets when I requested them, but only after I spoke to the International Sales guy. The telephone operator was quite unhelpful the first time. The International guy went out of his way to help when I bought the tank, even dropping it off at the air freight terminal. By the time I got the tank out of Customs here, it's cost had doubled, I think I paid US$125 airfreight and then about A$225 or so here, an expensive business, so I wasn't really very happy. keith wuenstel wrote:

> Gavin, On closer examination you hit the nail on the head re the problem. > The tank comes out of the injection mold process with a slight "roundness" > at the area where the petcock base sits on the tank. Not only doesn't it > provide a good seal but torqueing (sp?) down the bolts tends to squish the > gasket outwards. Yes, IMS should finish this area off better before > shipping! Thanks, yours was the first info that steered me to the REAL > problem! I'm pretty confident I can resolve it and get it to seal. > keith > > -----Original Message----- > From: Gavin Macfarlane [mailto:gavin@...] > Sent: Tuesday, March 07, 2006 2:50 AM > To: keithwuenstel > Cc: DSN_KLR650@yahoogroups.com > Subject: Re: [DSN_KLR650] Re: Petcock mystery > > > Keith, > > I've stayed out of this so far, I bought an IMS in about April 2005, we > had to file down the petcock seat on the tank two or three milimetres to > get a flat seal. Quality control was rubbish. I had airfreighted it into > Australia, so unfortunately returning it was way more than the tank was > worth. > > BTW I bought a spare petcock so that I can swap tanks whenever I want > without having to changeover petcocks > > keithwuenstel wrote: > >> Thanks for all the advice. I removed the stock O ring and bolted it >> back on the tank. Since this issue has been discovered I figured I >> better continue to test the seal with water. I have the bolts >> tightened down good but still have a drip about every 10 seconds. >> This is frustrating and IMS is going to get some feedback from me on >> this. Most critical area of the installation and the instructions are >> just plain lame. >> >>

-- Gavin Broadford Victoria Australia KLR650A18 DL650K6 Home of the DSN-KLR650 searchable archive at:- http://dsnklr650.gavinmac.com

[nakedwaterskier]

Is the easy pull clutch universal for all non-hydraulic ie cable set ups? And it hangs between the perch and gauges? Anyone got a pic of one installed? This isn't for my klr...klrs are pretty easy to pull. Thanks, Jeffrey Nakedwaterskier@...