2022 Kawasaki KL650

UNCONTROLLED RELEASE OF FUEL FROM TANK THRU TANK BREATHER SYSTEM WHEN MOTORCYCLE IS ON IT'S SIDE ON GROUND. DESIGN FLAW -- REDESIGN REQUIRED -- 2022 KLR 650 RELEASES FUEL FROM THE TANK BREATHER SYSTEM IN EVENT OF INTENTIONAL OR ACCIDENTAL MOTO BECOMING HORIZONTAL TO GROUND WITH NO MEANS OF FUEL SHUTOFF AVAILABLE EXCEPT BY TANK DRAINING TO LEVEL OF BREATHER WITHIN THE TANK. OCCURRENCE HAPPENS WITH UNDAMAGED AND FULLY OPERATIONAL FUEL SYSTEM WHETHER MOTO IS FUNCTIONALLY "ON" OR "OFF". ENVIRONMENTAL DAMAGE AND SAFETY TO PROPERTY, LIFE, AND LIMB, UP TO AND INCLUDING DEATH, CAN OCCUR FROM FUEL CONTAMINATION OR FUEL IGNITION CAUSING BURN RELATED INJURIES/DEATH/DAMAGE, OR FUEL CONTACT COMPLICATIONS. THIS OPERATIONAL SCENARIO IS INHERENT IN THE DESIGN OF THE FUEL SYSTEM, AND IS CONFIRMED BY A DOCUMENTED TRANSCRIPT OF CHAT SESSION WITH KAWASAKI SUPPORT ON 7/24/2023 (ATTACHED). IT IS ESPECIALLY DANGEROUS TO A PINNED/INJURED OPERATOR OF THE MOTO THAT CANNOT REMOVE THEMSELVES FROM THE PROXIMITY. IT IS ALSO HIGHLY PROBABLE FOR THIS TYPE OF MOTO THAT IS USED IN OFF-ROAD REMOTE OPERATION WHERE SITUATIONS FOR LOSS OF CONTROL OF THE MOTO ARE ENCOUNTERED FREQUENTLY. INCIDENT OF UNCONTROLLED FUEL LOSS WAS FIRST EXPERIENCED 7/4/2023 WHEN THIS VIN MOTO ACCIDENTALLY FELL TO THE GROUND ON IT'S RIGHT SIDE WHILE STOPPED AND "OFF". OWNER/RIDER AT THE TIME OBSERVED LEAKING FUEL FROM BREATHER SYSTEM WITH NO MEANS OF SHUTTING THE FLOW OFF. FREE FLOWING FUEL CONTINUED TO EXIT FROM THE BREATHER TUBE UNTIL THE MOTO WAS RETURNED TO VERTICAL POSITION. THERE ARE NO WARNING LAMPS, MESSAGES, OR OTHER SYSTEMS PRESENT TO INDICATE FLOW FROM OR STOP FUEL FLOW FROM THE BREATHER SYSTEM EITHER WHEN THE MOTO IS "ON" OR "OFF". THERE IS NO REDUNDANT FAIL-SAFE FUEL SHUT OFF IN THE BREATHER SYSTEM TO PREVENT LIQUID FUEL LOSS FROM THE TANK IN ANY ORIENTATION OF THE MOTO. RECALL/CORRECTIVE ACTION -- REDESIGN OF BREATHER TUBE ROUTING AS A STANDPIPE, OR ADDITION OF FAIL-SAFE FUEL SHUT OFF TO BREATHER TUBE.

The fuel pump failed while traveling northbound on hwy 127 in Glencoe, KY. The motorcycle lost power and had to be pushed to a parking lot and towed home because it would not start. No warning lamp came on. A recall exists for this part and I am waiting on its arrival at the dealership. No one was injured, though I had to contend with an unsafe situation pushing the bike alongside the highway.