I've been rebuilding the top end of of the engine on my 2006 KLX250s, it got a valve job and has a Bill Blue 351 kit ready to install. I took the engine out of the frame to do this, when I did I tore the breather hose that goes from the crank case to the air box. I ordered a new one from Partzilla and found out it is backordered. I haven't found one available anywhere else. The hose has a couple of bends built in but I'm wondering if I can get a straight hose the same diameter from the auto parts store and make it work. Any opinions about that or other options. It seems this hose is specific for the 2006-07 models, not the same as the klx300 or 09- models.

92191A in the diagram or part number 92191-1555

 

If possible, you could cut the tubing and insert a piece of PVC water pipe clamped on with a couple small hose clamps to fix the break.

 

I've ran into the backorder issue from Partzilla before too. I can usually call a dealership around me and have the parts department order one in from their warehouse in a couple of days. Might be worth a shot.

 

If the OEM hose is torn on the end/clamping section, using an elbow and the appropriately sized automotive hose would work if you're unable to find the OEM replacement.

The hose does not have to be high pressure like a heavily braided, stiff, thick-walled item. However, it should at least be emissions level rated, because just the heat and gasses from the crankcase will harden many rubber products very quickly.

To be honest, you don't absolutely have to have the crankcase hose vented into the airbox, but the nice thing is that it insures water not getting into an open, vented-to-the-atmosphere opening in some cases. If you run an open hose from the crankcase, just make sure there is ample down turn at the end of the hose or that it is routed to a place where water can't travel down the hose. If you do this it's good insurance to plug the airbox hole with a plug.

 

I just gave the local dealer a call and they are ordering one for me, hopefully it won't be backordered from there. I don't know why I didn't think of that before, I'm used to ordering all my parts online late on a Sunday night I guess.