Couple parts questions... - 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 11 Old 08-06-2014, 01:25 PM Thread Starter
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Couple parts questions...

Just joined the forum & I just purchased a 2006 KLR. Going over it I've run into three questions (so far).

1st. The suspension spring that is supposedly adjustable... isn't adjusting. It's set very soft and when I turn the tension nut notta. Is this a common issue? Easy resolve? Or... am I'm stuck with it unless I want (which I don't) to fork over $ for a new suspension spring/shock.

2nd. On the Riders left side (kickstand side) there is a part I'm assuming is missing that covers the battery... or helps firm it in place... attached is a picture of where I think it should be. I might be 100% off but what currently there is flimsy and floaty piece of metal that I think I could finger pinch out if I tried. I'm looking at the OEM parts diagrams but don't see anything. Pointers would help. (I'll try to get a better photo...)




3rd. The prior owner put 5,000miles (of it's 11K) her without ever doing a carb clean, spark plug, etc. I'm going to look into those soon to ensure its spick n' span. Difficult level to get in there for a learning wrencher?

TY in advance. I'm still learning how to navigate this site!

Vince

Last edited by klr4evr; 08-06-2014 at 10:33 PM. Reason: Edited to show picture.
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post #2 of 11 Old 08-06-2014, 02:18 PM
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1) Is the nut just spinning? It should be a five-position dealio. The adjusters on the '08s were prone to breaking. Gen1 was usually pretty good. Easiest fix is a used shock from eBay.

2) IONO, can't tell from the picture. The piece that holds the battery in is an L-shaped sheet metal piece with an ear at the bottom and a plastic piece riveted to the top. Should look like this:


3) If this idjit can do it, anybody can:





Tom

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post #3 of 11 Old 08-06-2014, 02:31 PM Thread Starter
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Whoa! Thanks Tom.

Yes, when you turn the nut to adjust the spring tension for the rear suspension nothing happens. :/

I'll try to take a photo or two of the battery cover I'm talking about later today.

AWESOME VIDS ON THE CARBS! Much Obliged.

Vince
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post #4 of 11 Old 08-06-2014, 02:45 PM
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eBay is a bit short on shocks right now and people are asking outrageous prices. You might place a WTB ad for a take-off.

Of course, you've not much to lose in trying to repair the one you've got. I've never had the adjuster apart, so can't be of any help there.

Tom

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“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

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post #5 of 11 Old 08-06-2014, 08:57 PM Thread Starter
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Here is a close up of the kickstand side battery cover that I'm trying to figure out what might be missing. You can see the amount of play these two parts have from one picture to the next.






Found another issue. In the following image:



I am missing part 120, a bolt, on the rider's right side. I took the same bolt from the left side to try to determine why... it doesn't screw into anything. Either whatever it's supposed to screw into is missing or entirely stripped. Yet there is nothing on the OEM pics that show me a replacement part for the nut or housing etc... I could probably make shift a Ace Hardware bolt system but is there a part I'm missing here?!?

Thanks in Advance AGAIN!

Vince

Last edited by klr4evr; 08-06-2014 at 10:40 PM. Reason: Show Pictures
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post #6 of 11 Old 08-06-2014, 10:37 PM
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Quote:
Originally Posted by ChutingVa View Post
Just joined the forum & I just purchased a 2006 KLR. Going over it I've run into three questions (so far).

1st. The suspension spring that is supposedly adjustable... isn't adjusting. It's set very soft and when I turn the tension nut notta. Is this a common issue? Easy resolve? Or... am I'm stuck with it unless I want (which I don't) to fork over $ for a new suspension spring/shock.

Vince

Before you rush off and try to buy a new shock check thread. Always good to do a forum search.


http://www.klrforum.com/showthread.p...ght=rear+shock

The likely culprit it seems is relatively easy to fix.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #7 of 11 Old 08-06-2014, 10:46 PM
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The KLR battery has a plastic cover that slides in on the top, covers most of the top of the battery and then the exposed side. It's held in place by a small melt plate and a single screw. Looks like you have the medal plate. Not sure what's going on behind it but it doesn't look right. It looks like this:



On the bolt it does not have a nut. It threads into the frame. You may be able to see the hole by looking under the rear fender. Likely stripped as you say.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #8 of 11 Old 08-06-2014, 11:05 PM
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klr4evr -

Excellent catch on the shock repair! I had forgotten that we learned that!

Does the plastic part of the battery cover look likes it's installed the wrong way around? It looks like the riveted fitting that is supposed to be on the top is on the side. I wonder if it is butchered up. The part that is supposed to be on the side has the clips for the drain hose molded in and would never fit along the top.

Tom

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“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #9 of 11 Old 08-06-2014, 11:14 PM
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Ya Tom you are right too. That metal clip that holds the fuse if I recall is showing. How anybody can get that piece in the wrong way is beyond me. It's likely been hacked.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #10 of 11 Old 08-06-2014, 11:57 PM Thread Starter
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I'll pop the seat to figure out what is up with the battery cover... My bike is an 06 the link about the rear shock looked more targeted at 08 and newer shocks. Thanks for the info! This site is def responsive!
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