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Discussion Starter #1
PO said he tried everything and so did the dealer. That may or may not be however is this a common known problem? Couldn't find anything in search so maybe it's just mine. If so, any suggestions besides check gas cap for blockage?
 

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First two things come to mind: 1. Are the overflow tubes attached to the correct fittings? Blue dot hose to forward fitting. 2. Is the fuel sender leaking? Need more info to give any more ideas....
 

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Discussion Starter #3
Thanks for trying to help bcalan. Hoses are good I believe but where would fuel sender be leaking? Have a pic please? Not very familiar with the bike yet, just got it.
 

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Fuel sender confusion on my part. My '90 Concours has an overflow under the area where the fuel sender unit bolts to the tank bottom so if it leaks the leaking fuel will be directed through a tube to the ground. V doesn't have that. Check this link: http://www.bikebandit.com/oem-parts/2011-kawasaki-versys-kle650c/o/m148664#sch706784 and you will see both overflow tubes run from the fuel cap area through the tank. I would fill the tank, block the rubber tubes, gently blow some air through each tube (NOT with a compressor) and see if there are any bubbles in the gas, or if I could hear the sound of any air escaping inside the tank. You didn't say if it was both tubes or whether or not it was a continuous leak. I would suspect a holed or disconnected tube. Digging further I would remove the fuel cap and look. Digging even further I would remove the empty tank, take off the fuel sender, remove the fuel pump and look into the tank with a good light carefully checking the internal lines. That's all I can suggest without actually being there.
There is some chance, if the amount of fuel coming down the overflow tube is slight, of evaporation coming down the vent tube. High ethanol gas? Gas cap vent valve not sealing? Gas cap valve tampered with to eliminate the "teakettle" whistle when the vent valve relieves tank pressure? Throw enough stuff on the wall something will stick. I doubt if a dealer mechanic working on commission would give this problem the time it deserves.... Good Luck.
 

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Discussion Starter #5
Dang that's comprehensive. Thanks a lot. I have lots of work ahead of me. Will report back on my progress and hopeful resolution of the problem.
 
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