Rebuild/ 685 kit cost? - 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 12 Old 04-07-2020, 04:35 PM Thread Starter
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Rebuild/ 685 kit cost?

Hi, I picked up a 2003 klr 650 with 20k miles on it about a month ago and it seems to have a weird rattle or something on the left side of the engine. I really like the bike but I'm having a hard time trusting it with the noise and a little more power would be nice. Just curious if anyone has any idea on roughly how much a complete top to bottom rebuild with a 685 kit would cost or if it's even worth doing? Also if anyone has any suggestions on a shop near saint george utah that would be awesome. Thanks.
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post #2 of 12 Old 04-07-2020, 04:51 PM
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Ck3191, welcome to the forum. Have you read this yet? https://www.klrforum.com/introductio...kes-avoid.html


Next up,
https://www.souperdoo.com/stuff%20th...bout/doohickey

Read about what may be causing the 'rattle' and watch the videos twice.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 12 Old 04-07-2020, 06:34 PM Thread Starter
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That's by far the most informative response I've ever gotten on a fourm, thank you. I made the mistake of adjusting the doohickey without checking it out first. Now that I know these things listening to it with a stethoscope I could definitely see it just being a little bit of slack in the cam chain. The real question is it as easy as the videos make it look? Lol
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post #4 of 12 Old 04-07-2020, 07:47 PM Thread Starter
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Do you happen to know of any good websites for parts?
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post #5 of 12 Old 04-07-2020, 08:43 PM
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The best place to get Kawasaki parts is at your local Kawasaki dealer, if you have one. Support the locals! I don't mean to prejudice you, but any business with "Powersports" Or "Motorsports" in the name that lives in a big box building and sells every brand is not your local Kawasaki dealer. In truth, they probably got into the business by running three or four family-owned businesses out of business. You might want to beware of any business, say on Red Hills Parkway, with "Powersports" in the name. I don't mean to be a dick, but...oh, wait, that ship has sailed, hasn't it?

I don't have a worthy local dealership (I have Del Amo Motorsports and when and if they finally die I am not going to piss on their grave. I don't like standing in line.) and I need to shop the internet.

For OEM parts I find Partzilla to be quite reasonable in terms of price, availability, shipping cost and speed, and customer service.

Tom [email protected]

“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.
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post #6 of 12 Old 04-08-2020, 06:47 AM
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Yes, support your local dealer if you can!

For a 685, contact Eagle Mike. If you call, he'll even talk to you!!
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post #7 of 12 Old 04-08-2020, 12:40 PM
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Quote:
Originally Posted by Ck3191 View Post
That's by far the most informative response I've ever gotten on a fourm, thank you. I made the mistake of adjusting the doohickey without checking it out first. Now that I know these things listening to it with a stethoscope I could definitely see it just being a little bit of slack in the cam chain. The real question is it as easy as the videos make it look? Lol
And I will offer a correction to your posting, "Balancer Chain".

Get to know your local Kawasaki dealership, if you have one. And at least give them the opportunity to compete with on-line sales, with their service. They may surprise you.

I most often use RMATV/MC for on-line oem parts. Free shipping at $75 +.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #8 of 12 Old 04-21-2020, 01:14 PM Thread Starter
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Yeah I wont be going over to the factory I've never heard anything good about them. I've watched all those videos on the doohickey replacement 20 times now. Which are very well made good job Tom Schmitz and thanks for taking the time to do it. My only concern from reading through a couple of horror stories on here is the woodruff key. Is there a way to know for a fact that you have the rotor properly aligned before torquing it down? I'm probably over thinking it but I'd hate to be another story of smashing/shearing the thing.
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post #9 of 12 Old 04-21-2020, 01:26 PM
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Quote:
Originally Posted by Ck3191 View Post
Yeah I wont be going over to the factory I've never heard anything good about them. I've watched all those videos on the doohickey replacement 20 times now. Which are very well made good job Tom Schmitz and thanks for taking the time to do it. My only concern from reading through a couple of horror stories on here is the woodruff key. Is there a way to know for a fact that you have the rotor properly aligned before torquing it down? I'm probably over thinking it but I'd hate to be another story of smashing/shearing the thing.
When ready to re-assemble flywheel, CLEAN & DRY the tapers. Then use (a hammer) an awl to place 2 small stipples onto the lower half of 1 side of the woodruff key and gently tap the key down into the fly-cut of the crankshaft. This keeps the key from too easily slipping out of place.

pdwestman
Modify at "YOUR OWN RISK"!

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

Last edited by pdwestman; 04-21-2020 at 01:53 PM. Reason: Hammer and awl
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post #10 of 12 Old 04-21-2020, 02:05 PM Thread Starter
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Yeah I'm going to do that, I ment is there a way to tell If it is properly aligned in the key way of the rotor? From the videos it seems as simple as just aligning it as best as possible and giving it a little twist back and forth until it seats back over it. Will it spin freely on the crankshaft until it is aligned with the key?
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