Interchangeable Parts - 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 21 Old 10-06-2017, 01:22 AM Thread Starter
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Interchangeable Parts

Hey So I'm trying to either find a list or make one of parts that are interchangeable between gen 1 and gen 2 klr 650s also between the 250s Nd 650s parts look so similar but don't wanna order something just by looks lol. Thanks a ton!!
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post #2 of 21 Old 10-06-2017, 10:06 AM
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It would probably be easier to make a list of parts that do NOT interchange! ;-) though there are some differences between Gen1's and Gen2's, most parts will swap back and forth i.e. swingarms, suspension linkage, forks & tripples, heads, ignitions, etc. etc. some require part swap as a group rather than an individual part.


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post #3 of 21 Old 10-06-2017, 12:30 PM Thread Starter
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ahhh ok awesome! some of the things i was looking for are a piston head and cylinder as well as the purple seat, I have a 94 650 and want the purple seat to go with the teal but cant find one for it lol, loads for the 250 any ways is there some where that has a list of things that don't fit. i know plastics and tanks and other obvious ones lol but yeah. thanks for the help
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post #4 of 21 Old 10-06-2017, 02:27 PM
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That's a huge task. To Dave's point, almost anything can be swapped, but there are lot's of 'except fors'.

Seats are interchangeable, except for the Gen 2 seat has a clip that fits into the tank.

Tanks are interchangeable, except for the Gen 2 has brackets for the fairing Tupperware and that clip for the seat.

Wheels are interchangeable, except for the brake rotors.

Engines are interchangeable, except for you have to keep whatever stator you originally had.

And so on...

Heads and cylinders are fully interchangeable, BTW, except for nobody would put a pre'96 cylinder on a later bike unless they had to. Most pre-'96 stuff would not be preferable on a later bike, except for the clutch in a kick-start installation. The pre'96 balancers should be changed out for later ones.

There's really very little that can't be interchanged with some imagination and work. My bike2009 has a ton of Gen 1 stuff on it.

As to 650>250, I got nothin'.

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post #5 of 21 Old 10-07-2017, 06:57 AM
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post #6 of 21 Old 10-07-2017, 08:55 AM Thread Starter
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Ahhh ok sweet so I should look for a 96+ cylinder and head. And if I wanna do the kick start add on i could grab the parts from the 600 then? I know mine has alot of the parts already necessary for the kick being a 94 I think it's just cracking the case popping the plug and adding a shaft and a lever, I may be wrong I only briefly glanced at the forum for that.
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post #7 of 21 Old 10-07-2017, 10:29 AM
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Everything You Ever Wanted To Know About A KLR Kickstarter But Were Afraid (or too smart) To Ask

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


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post #8 of 21 Old 10-07-2017, 10:36 AM Thread Starter
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Ok sweet thanks!
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post #9 of 21 Old 10-07-2017, 10:53 AM
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Quote:
Originally Posted by Sivaas View Post
Ahhh ok sweet so I should look for a 96+ cylinder and head...
The cylinder was redesigned in '96. The base of the cylinder is thicker and the liner is thicker. There's nothing really wrong with a pre-'96 cylinder, but it can't be bored out to fit a 685 piston. It is capable of only a small over-bore, so most pre'96 owners will find a later cylinder to use if they ever intend to install a big-bore kit.

Heads are pretty much same-same.

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post #10 of 21 Old 10-07-2017, 11:55 AM Thread Starter
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Ahhh ok cool. I've gotta replace mine so I'll probly look for a newer one. I'm guessing there is a thread that talked about boring out the cylinder, like pros cons then the process?
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