Interchangeable Parts - Page 2 - 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 #11 of 21 Old 10-07-2017, 12:10 PM
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Nothing so concise, I fear.

Some do it for the modest gain in horsepower and torque, others do it to give life to an old, tired, engine. It's a solid cure for oil burning issues.

I think the best reason is the second reason, as its $/hp ratio isn't spectacular.

There are quite a few options. The 685 is a tried-and-true set-up, but big bore kits and motorcycles go back to before dirt was new. There is no magic or mystery to it. There are pistons and ring sets available from JR, Arias, Wössner and others in +.5, +1, +1.5, +2mm configurations. Any of those, and a post '96 cylinder, can be taken to an average automotive machine shop to get the bore and hone done, then brought home and assembled with little trouble.

There is a larger overbore, the 705, that requires a special cylinder because the over-bore is quite large. Its $/hp ratio is even less spectacular.

If your engine is burning oil, consider that $500 buys a lot of oil if you are capable of keeping an eye on the oil level.

Tom [email protected]

“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

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


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post #12 of 21 Old 10-07-2017, 12:36 PM Thread Starter
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Ahh ok cool I haven't noticed it burning oil yet but I have put many miles on it yet. Still ordering parts and such to get it ready to ride only paid 900 for it tore the top end down once replaced all the gaskets because it was burning coolant (white smoke) and found the piston and cylinder was marred up I cleaned both up pretty well but still will need to be replaced. Probly will do that this winter when I get some more $$ and time. I work in a machine shop so I could do it myself if need be but I think I'll just swap them and call it a day. Also it's still smoking even after the gasket change so there's probly a crack somewhere I couldn't see. I looked at everything realy well but nothing stood out. Maybe I'll find it the 2nd time. Need to probly replace the valve head too but well see if I can find one cheep enough.
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post #13 of 21 Old 10-07-2017, 01:09 PM
Pretty in Pink, dunno why
 
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Look for a missing or poorly sealed air filter and/or a hole burned in the air box by a bad muffler connection and/or an un-plugged drain hose on the clean-air side of the air box. The piston looks like it might have sucked up some dirty air.

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“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

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


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post #14 of 21 Old 10-07-2017, 01:53 PM Thread Starter
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Ahhh ok cool I'll give that a look see. Thanks!
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post #15 of 21 Old 10-13-2017, 12:53 PM Thread Starter
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hey does anyone know if the engine guards for the gen 2s will fit on the gen ones? was gonna post the link to the ones i was looking at but they are tusk bars for gen 2. but i like how these connect up under the tank where as the gen 1s connect back by the master cylinder.
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post #16 of 21 Old 05-13-2019, 06:04 AM
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I brought my 2009 KLR650 from Canada to Europe, only to find the new model isn't TUV approved in Europe.
So I'm thinking I will look for an older KLR650 and move all the parts from my low-km 2009 model to the old one.
It seems from what you guys are writing that this might be a fairly easy task.

My main question would be: Are the frames almost interchangeable?

This will allow me to "age" my 2009 (and save on insurance, etc!).
I'd love to get a 1989 model or older, making my a vintage model.

Does anyone know what would be the main issues I likely would run into in doing this?
I would move as many parts over as I can.
I could do a little welding to make certain items fit, but will not be bending the frame, etc.
I'd love to strip the old bike to the frame, move engine, tank, seat, front forks with all instruments, headlight, etc over to the old bike.

Does anyone know how similar the frames are?
Especially:
1. Will the engine fit the older frame?
2. Will the front forks fit the older frame?
3. Will the rear forks/tire, etc fit the old frame?
4. Will the fuel tank fit the old frame?

Thanks!
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post #17 of 21 Old 05-13-2019, 08:45 AM
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The only issue moving a Gen 2 into a Gen 1 frame will be the mounting of the fairing. The hardpoints on the frame are different. I don't know of anyone who has done it so I can't point you to a 'how to', but it doesn't seem insurmountable.

1. Will the engine fit the older frame?
Yes, it will, but there is bracketery for the Air Injection System that must be moved over and a boss on the Gen 2 frame that provides clean air to the AIS that the Gen 1 frame won't have. I presume that you would take the electrical system to the old frame; if you don't then you will need a Gen 1 rotor and alternator cover to work with the Gen 1 ignition.

2. Will the front forks fit the older frame?
The fork tubes on the Gen 2 are larger in diameter, so you must move the entire fork assembly, including the triple trees, over. Given that, yes, easily.

3. Will the rear forks/tire, etc fit the old frame?
Yes, but you might want to keep the Gen 1 suspension pivot when you transplant the swingarm. You will have a bit more ground clearance and rear suspension travel.

4. Will the fuel tank fit the old frame?
Yes.

Tom [email protected]

“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

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


Sting like a butterfly.

Last edited by Tom Schmitz; 05-13-2019 at 08:47 AM.
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post #18 of 21 Old 05-13-2019, 09:02 AM
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Thanks Tom!

Those answers are great! Both because they answer the questions, and because they bear good news which solve my problems and worries.
Now I'm only down to finding a gen 1 bike, preferably in Norway
Maybe that will be hard, cause who wants to sell a good bike like that?
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post #19 of 21 Old 05-13-2019, 09:05 AM
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Just come to think about something

I have noticed there was a KLR 600 at one time. Will the gen 2 650 parts fit the same on a KLR 600 as a KLR650?
Are they virtually the same or quite different?
Should I avoid the KLR600 for any reasons, or are they weaker/worse or maybe better for any reasons?
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post #20 of 21 Old 05-13-2019, 09:52 AM
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Originally Posted by Ingvar View Post
Just come to think about something

I have noticed there was a KLR 600 at one time. Will the gen 2 650 parts fit the same on a KLR 600 as a KLR650?
Are they virtually the same or quite different?
Should I avoid the KLR600 for any reasons, or are they weaker/worse or maybe better for any reasons?
I will say that about the only part that will directly swap from a 600 to either Gen of 650 is the front fender. The bolt spacing is identical.

Other than that there too many differences between the 600 & 650's to directly interchange parts.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 83,000+ miles & counting
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