My first Thumper........ - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 4 Old 10-23-2007, 10:01 AM Thread Starter
Join Date: Oct 2007
Posts: 2
My first Thumper........

Well, I finally got it, my first KLR 650. It is a 99 with 7400 miles on it. As far as I can tell it is bone stock with the exception of a Big gun exhaust. I have worked with mods on cars and trucks for a long time but I have little experience with bikes. The only thing that seems weird with this bike is the clutch lever, it seems very hard to pull in and disengage the clutch. The only other bike I have ever owned was an old Kaw' 750 triple street bike, the clutch was much easier on it. Any ideas? Also what are the first things I should check out, somethin about a doohickey?!?!?!? Lastly, is there a particular dealer who specializes in aftermarket parts for these bikes. I will try and post some pics of the bike later.

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post #2 of 4 Old 10-23-2007, 10:24 AM
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Join Date: Sep 2006
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I'll address your clutch lever..

The cable runs in a tube and that tube, as well as the entire cable needs to be lubed. Once lubed with a light grease, you'll find it operates much nicer..

I tend to use a product called Maxima Chain Wax for cable lube. It goes in as a liquid and sets up as a tacky, light grease.

Doohickey?? Never heard of it..

Does someone have the link available for this gentleman???
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post #3 of 4 Old 10-23-2007, 11:20 AM
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Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980
I'll address the Doo. It is quite important to make sure your doohickey is changed if it hasn't been by the PO. Here is the link for the procedure, it is not as difficult as it appears, about two hours of work taking your time following each step precisely. You can pick up the Doohickey upgrade at or at I recommend this before anything else. The doo runs about $40. I tried to find the bolt to remove the flywheel at my local hardware store but noone carried that thread size. Just order it from Fred at arrowhead and that way you will have it when your friends get KLR's and you need to do their doo's. A standard 1 1/4 wrench will work fine for holding the crank to break loose the flywheel. I didn't bend or reweld my wrench at all. If you have any more questions feel free to ask. OH, an electric impact was perfect for getting the flywheel off, but use a torque wrench to put it back on with.

Here is the procedure link:

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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Last edited by DXKLR; 10-23-2007 at 11:33 AM.
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post #4 of 4 Old 10-23-2007, 11:30 AM
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Join Date: Sep 2006
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As far as the aftermarket parts, there's a ton of them out there, since that version was made for years without many changes. Even a great deal of the parts for the new 08' model work with the past 20 years worth of bikes.

A lot depends on what you're after for aftermarket stuff.. List what you're after and someone here will fill you in on a location or two, and what to expect for price and any issues with that aftermarket part.
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