All the help - 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 2 Old 03-06-2020, 04:34 PM Thread Starter
1st Gear
Join Date: Jan 2019
Posts: 20
All the help

Hi, hopefully i can let you guys understand where I am with my 87 klr in life... The bike is stripped down and has been for a year, the motor's in one room and the frame is in my closet. I really only have hand tools and that's it, so there's that. Hopefully you have the stomach for a story... I picked the bike up for 800 bucks, even Mud packed and showing no signs of life, and at 49k miles. I had hoped it was something simple like a fuse, like an experience I had before with another bike. A good cleaning and after a few long hours of trying to get it running I ended up pulling the harness thinking it was the problem, turns out just a corroded stator wire shorting out, and maybe some of the harness cause it was a mess too. I've since gotten the harness wired as best I could not an electrician but it looks fine, got the book to help. Over time with it sitting with the instruments off and such I decided I could clean deeper with it apart more and if I wanted to I could get the frame painted to prevent future rust. 87 to now with very little rust, not too bad, I just wanted it to have another 35 years rust free if I could xD why not at this point. Had the stuck swing arm piviot bolts holding the motor in place, went wacking and heating like never before finally just tore the oil seals out and put a blade in there and cut the bolts and the sleeves. Okay okay so some of this may have been a bit much but hey I do like projects and biting off more than I can chew. On the brightside I just got bolt replacements in from eBay and seem good, now waiting to order the bearing/sleeve/oil seal kits from pivot works. I'm still open to painting the frame but it seems unnecessary tbh, and I'm on a budget... Just wanted to share my story and maybe some of you can offer any advice or any budget mods you'd suggest I get ready for, there's so many threads to read through and tbh some I don't understand. I'm hopeful for the future and can't wait to ride it but I have alot of work ahead and I'm a big noob. Thanks for reading!
Thomas Matthew McClain is offline  
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post #2 of 2 Old 03-06-2020, 06:40 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,195
Be Certain to PLUG those 2 stupid holes in those lower suspension pivot mounting tubes that let the water inside & corroded that pivot bolt in!
One can simply use RTV silicone or thread them for screws with thread locker.

If one can afford to purchase a pair of USED 1996-2018 engine balancer sprockets and the spacer washer behind the upper rear balancer sprocket it will probably smooth out the vibrations of that Early Gen 1 engine A BUNCH! It sure did on mine, just a couple of weeks ago.

The springs in my 87 sprockets were fully intact and the older EM extension spring and Doo-Hickey were doing their job, perfectly. But Wow, what a difference in over-all vibe reduction & over-all engine noise.
I should have done it 10-25 years ago!

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
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