I'm going through my carbs trying to figure out why the bike is running poorly and leaking gas.

Found put part of the problem was the repair that I tried to make to one of the crap K&L o-rings didn't work.  Gasoline-1, Hondabond-0.  8-(

Since none of the import bike places keep more than $9.72 worth of inventory on hand, I headed off to the H-D dealer on a hunch. 

I've heard that the Sportster and KLR650 share the same carb body and the diaphragms are interchangeable.  So that got me thinking--if the diaphragms are interchangeable, maybe the float bowl o-rings are too.  So I checked the part numbers from Kawi and the o-rings from the KLR are the same ones as the Connie.  Kawasaki wants around $10 plus shipping for each one.  And I'd have to wait.

So off to Grand Canyon H-D in Mayer I go.  Told the tech I needed a float bowl o-ring for a 2001 XLH883, but any year from 1992-2003 (at least, maybe later) will work.

Here's what he came back with:


The part number is 27577-92.


And here is the o-ring in the float bowl:


Note the little circle--that's for the accelerator pump and will have to be carefully snipped off.

Cost was $4.25.  Kawasaki ought to be ashamed of what they charge for their service parts.

Not encouraging anyone to go the darkside, but if someone is in desperate need for a carb o-ring try H-D.  Some of the dealers are open 7 days a week and they actually stock parts.

Don't know about any 'dark side' issues, but I for one find the information extremly valuable!
Thank you very much!

Don't know about any 'dark side' issues, but I for one find the information extremely valuable!
Thank you very much!

You're welcome.  I've pinched an o-ring before and the Hondabond just didn't hold up.

I just realized something.  The part number on the float bowl o-ring starts with 92.  In Harleyese, that means that that part number was first used in 1992.  The ones before '92 had the accelerator pump o-ring separate.

I think I also found a part number for the drain screw o-ring.  I am going to Phoenix tomorrow, I'll take a float bowl and drain screw with me to check.

If the parts work, the cost to do the float bowls & drain screws will be $20 for everything.

I'm also gonna swing by an indy and see what it would cost to use all James gaskets.  James gaskets are good stuff and made in the USA.

Good info.  Thanks.

You can also get your carb jets from the HD shop for the exact same reason......

So how long did it take to scrape the chrome off the gasket?   

or you could simply make a call here:
http://www.murphskits.com/catalog/product_info.php?cPath=1_107&products_id=329
and plop $20 for all 4, call on a Wednesday and check the mailbox Monday morn.....free shipping.....

but then you probably haven't been here long enough to know our secrets.....

oh, and the reason the kaw parts are so high is they have to ship those HD rings to japan, and pay someone to cobbledick them and trim them down...

I've ordered stuff from Murphs before.  Wanted to see if I could source some locally.

The K&L o-rings don't fit properly.  They need to be stretched to fit because their molds are off.

I'm going to try some James gaskets because I like to buy stuff made in the USA when possible.

The H-D stuff is made in Japan.

Oddly enough, the same O-ring from Suzuki costs $5 and change.  So I guess Kawasaki likes playing its customers for suckers.

or you could simply make a call here:
http://www.murphskits.com/catalog/product_info.php?cPath=1_107&products_id=329
and plop $20 for all 4, call on a Wednesday and check the mailbox Monday morn.....free shipping.....

but then you probably haven't been here long enough to know our secrets.....

oh, and the reason the kaw parts are so high is they have to ship those HD rings to japan, and pay someone to cobbledick them and trim them down...

I probably missed it - what is the suzuki part number?

You didn't miss it--I didn't put it up.  DOH!!  My notes are at home.

You can look it up under any year of Suzuki 600 Bandit.

I guess the 600s used Keihin CVKs.

I'm going to try some James gaskets because I like to buy stuff made in the USA when possible.The H-D stuff is made in Japan.

 
and your bike was made where? or should I say the parts were made where?
 

and your bike was made where? or should I say the parts were made where?
 

I ride what I can afford. I miss the cheap parts, dealers that don't suck and the non-messy oil change that only required a stubby standard screwdriver.
If I could afford another solid-mount XLH I'd be on it in a heartbeat without looking back.
But I can't.  I can afford what I've got.
Better to ride the fragile, expensive-to-repair Kawi than not ride at all.

Why should I not try to buy domestic parts for my motorcycle?  Please explain.

...Better to ride the fragile, expensive-to-repair Kawi than not ride at all.

Why should I not try to buy domestic parts for my motorcycle?  Please explain.

I hardly consider the Concours fragile, or expensive to repair...based on how many 86 and up ones are running around today, or the ones with bonifide 200k odometer readings I've seen... 

please don't take my joking the wrong way, I like low priced parts that work also, and I along with Steve in Fla have probably installed hundreds of K&L bowl gaskets....stretch them, install, and all is good. You only stretch it once during install, no big deal. Easier to stretch one than SHRINK one...

as for James kits, I think you may be confusing "KIT made in U.S.A.", with "ALL PARTS in Kit MANUFACTURED in the U.S.A."....big difference. call them.
 
(they do have good prices though, I need to check with them as the prices for diaphragm/slide assy is great ($44?)

frugal is all good man, nothing wrong with it.

"and your bike was made where? "
I still have the handle bar tag somewhere that notes my 2000 was assembled -- which is as close as a vehicle gets to being made -- in Lincoln, Nebraska.

Had never heard of James Gasket before -- probably because I've never been a Harley type -- but it looks like a
JGI-27577-88 would be perfect alternative.

I hardly consider the Concours fragile, or expensive to repair...based on how many 86 and up ones are running around today, or the ones with bonifide 200k odometer readings I've seen... 

please don't take my joking the wrong way, I like low priced parts that work also, and I along with Steve in Fla have probably installed hundreds of K&L bowl gaskets....stretch them, install, and all is good. You only stretch it once during install, no big deal. Easier to stretch one than SHRINK one...

as for James kits, I think you may be confusing "KIT made in U.S.A.", with "ALL PARTS in Kit MANUFACTURED in the U.S.A."....big difference. call them.
 
(they do have good prices though, I need to check with them as the prices for diaphragm/slide assy is great ($44?)

frugal is all good man, nothing wrong with it.

$44 for a diaphragm blows your mind, eh?  I heard about the interchangeability a long time ago on advrider from a KLR owner.

Had never heard of James Gasket before -- probably because I've never been a Harley type -- but it looks like a
JGI-27577-88 would be perfect alternative.

James even designed their own intake manifold gaskets--totally different than the H-D factory pieces.  Work better too.

I'm going to email or call them this week and find out if all their stuff is molded here.