Question about 2008 KTM 200 EXC

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Vent hose on 99 ktm 200cc

I am having trouble finding the attachment point for the vent hose on my bike. After having the engine worked on it was returned to me without this hose in place. I se a hole in the side cover where this hose passes through but I don't know where it goes from there or what it attaches to. Is there a barbed fitting inside the case? Could I send a photo of the engine with a screwdriver pointing to the location of the hole this hose passes through? I have contacted several dealers and looked at their pictures bur haven't been able to determine what this hose is for and where it attaches inside the cover. I love this bike and the hose is the only thing holding up a new ride after the rebuild!

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  • Paul Thoegersen
    Paul Thoegersen May 11, 2010

    Send a photo....where is the other end attatched? what's being vented?


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Did you ever find your answer?? I have the exact same problem!

Posted on Aug 31, 2009

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Hi mark first stretch out the harness beside the bike to be sure it's the right one for it. Then look at each connection on the bike and harness try find the mid point ie. the engine electrics and connect them up then work your way forward. Then backwards the harness will have to be inside the frame to avoid damage especially around the seat area. When the harness is in place fit lights and whatever else is there and wire it as you go. If you find a few spare connectors don't worry many harnesses are made to suit other models. Have fun.

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I have a led kit for my 2007 kawasaki vulcan nomad 1600 and I need to take the gas tank is

This applies to 99 and later FI models. (Note, Removal for Carbed Bikes is simpler only needing the fuel line removed from the petcock plus a vent line or two)

It will be make things much easier if you drain the tank if you're doing this by yourself. Otherwise you'll probably need a helper to hold the tank while you disconnect hoses from the bottom. All you need is a siphon hose (and what teenager has never used one of those on dad's car eh?). If a piece of 1/2" garden hose isn't handy visit your auto supply store and pick up three or four feet of clear (so you can see the gas coming toward your mouth) 1/2" id (or close) plastic fuel line. Sometimes it's sold off a big spool sometimes pre-packaged hanging on a peg. You can also find clear hose at many hardware stores (even Home Depot & Lowes).

Follow the instructions below up to #8 (so the tank is loose) and put a block of wood under the rear of the tank so it's tilted forward slightly. Put your hose in the tank, apply suction (hopefully without getting a mouth full of hydrocarbon) and transfer fuel to another container.

Special Caution: Do NOT remove the pressurized hose if the engine has just been running or even if you've had the key on in the past few minutes. If the hose is removed before pressure has a chance to bleed off you WILL spray gasoline all over your bike and maybe yourself.

1. Remove the seat
2. Remove the chrome instrument surround (take out bolt and slide the surround forward)
3. Slide the speedometer assembly forward and off (if digital), lift out and disconnect speedo cable if analog.
4. Disconnect wires from speedometer assembly and set assembly aside in a safe place
5. Disconnect the other 2 wire connectors. It'll be handy to have a small flat blade screwdriver for this so you can push down on the catches while pulling the connectors apart
6. Remove front cap nut and rear tank bolt. Both are 12 mm.
7. Remove the one or two vent hoses you can see at the rear of the tank. (California bikes have two vents, most others use one).
8. Lift the front of the tank and put a folded shop towel on top of the engine right under the fuel lines. You'll get a few drops out of the lines when they're unplugged.

At this point a helper will be real handy to hold the tank up while you disconnect the fuel and vent lines especially if there's any fuel in the tank.

9. Remove the the fuel return hose...(the one with the metal clamp). A little gas might come out.
10. Remove the pressurized fuel hose...this one has a "squeeze" fitting. You just squeeze on each side of it with your fingers, push the fitting up toward the tank just a little then (while holding the 'buttons' in wiggle side to side to release it. A few drops of fuel might drip but the rag should take care of it.
11. Remove the square plastic piece and vent hose on the right side of the tank. It's next to the fuel line you just removed and covers some electrical connections.
12. Remove the vent line toward the rear of the tank. This line runs to the collection of vent hoses near the rear of the engine.
12. Finally, Remove the tank.

It probably took you longer to read all that than to actually do it and once you've removed the tank you won't hesitate to do it again for general maintenance especially if there's any chance you could drop something on it.

Re-assembly is in reverse order.

Caution!!!!! The hose with the 45 degree angle plastic connection with squeeze sides must snap into place when it's re-attached to the tank. If you don't hear it snap then you are at very high risk of having the hose slip off the tank fitting when the line pressurizes or maybe as you're rolling down the street. When that happens you will be pumping gasoline directly onto the top of your rear cylinder. A decidedly bad thing. Be Certain It Snaps!!!!

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Advise them that you are aware that the State Attorney General, Michael Cox, has written KTM twice and gotten no response from KTM., copies enclosed. Without satisfactory resolution to the issues at hand you have been advised to seek legal council and pursue a punitive lawsuit against KTM for breach of contract (warranty ), and damages. Once the lawsuit ha been filed you will accept no agreement less than a full refund of the purchase price, tax, title and license and documented expenses, including legal fees. You will deliver the bike to the KTM agent who sold it to you. You need to find an attorney and advise KTM of his name and contact information.

Interview several attorneys. Present what documentation you have at the interviews. Suggest a class action lawsuit? Your agreement should be no fees or charges of any kind will be paid other than through a judgment in your favor that covers attorneys charges and fees. The attorney must agree to represent you from the point of filing a lawsuit to a favorable decree by the court. KTMs' attorney will immediately check out the strength of your attorney. A one man legal show is no match for a law firm of 15 lawyers. If you engage a divorce attorney to act on your behalf you have already lost. Realize this means KTM will turn the issue over to the corporate attorneys and will not be able to correspond with you other than through their attorneys. You will need to stop riding the bike and park it in a safe place protected from weather and tampering. Chances are it will be a few years before any resolution is had.

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*Help me out. Rate me!

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1 Answer

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Hope this helps.
(If it does then please mark this as 'useful')
Ride Safe

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Can I get a “very helpful” rating on this answer?

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Bikes normally have vent/drain hoses for overflow and whatnots. Nore than likely, the hoses you see are them. Trace them to find out for sure. As for your bike, you might have to do a little carb tuning. But to start simple, run some cleaner through. Maybe you just have a little gunk in there. I also suggest if you do not have already, purchase a repair manual. It will help you troubleshoot in case you need to do a little work.

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