Need help may have broke rear shock - 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 24 Old 08-19-2010, 06:51 PM Thread Starter
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Need help may have broke rear shock

I was just adjusting rear shock and must have gone too far because it jumped clear back to "1" and now it wont adjust anymore. How do i fix this i dont have to replace shock do i?
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post #2 of 24 Old 08-19-2010, 08:03 PM
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Are you talking about the top bolt (for preload setting on spring) or the damping setting on the bottom of the shock? If it's the top, you may have broken the bolt, It won't really hurt any thing but you will not be able to adjust it any more. If it's the bottom dial for damping, you should be able to continue turning it and it will click to the next setting. Keep in mine on both adjustments, there is only one way you should be turning them. The top both should only go clockwise and the bottom dial only to the right > . If you go all the way to the 4th setting, it should start over at 1.

2009 KLR 650
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post #3 of 24 Old 08-19-2010, 08:11 PM
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MongoNv-

Is this on an '08? It was a known issue on the first Gen2 bikes and Kawasaki fixed it under warranty.

You definitely should try the warranty route, as a new shock will be required if the adjuster snapped. An expensive proposition.

If Kawasaki won't honor a warranty claim (due to the age and it being out of warranty) then, depending on your weight and riding style, your options are to find a stock shock or go for one of the aftermarket units.

The shock is different on the Gen2 bikes; I don't believe that a Gen1 shock will work. The bottom clevis and bolt are different.

Anybody know if the above statement is absolutely true?

Tom

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post #4 of 24 Old 08-19-2010, 09:48 PM
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Gen 1 and Gen 2 shocks are swappable but I think you need the corresponding bolts to make it work.
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post #5 of 24 Old 08-19-2010, 09:55 PM
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Originally Posted by SLO-KLR View Post
Gen 1 and Gen 2 shocks are swappable but I think you need the corresponding bolts to make it work.
Good to know! Gives MongoNv more to choose from if he decides to go the stock route.

Thanks!

Tom

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post #6 of 24 Old 08-19-2010, 10:22 PM
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Quote:
Originally Posted by MongoNv View Post
I was just adjusting rear shock and must have gone too far because it jumped clear back to "1" and now it wont adjust anymore. How do i fix this i dont have to replace shock do i?

How to fix the preload adjuster.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #7 of 24 Old 08-19-2010, 10:24 PM Thread Starter
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the bike is a 09, and i bought it in march. I believe it has a one year warrenty? When i was adjusting it i wasnt sure if it was maxed out or not so kept turning when it dropped all the way to 1 now it just turns and does not adjust. Can you just replace the bolt? If so how big of a job is it? Thanks for your responses.
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post #8 of 24 Old 08-19-2010, 10:30 PM
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Spec -

Thanks for that. I learned something.

It's a good day now...

Tom

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post #9 of 24 Old 08-19-2010, 10:34 PM
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Quote:
Originally Posted by MongoNv View Post
the bike is a 09, and i bought it in march. I believe it has a one year warrenty? When i was adjusting it i wasnt sure if it was maxed out or not so kept turning when it dropped all the way to 1 now it just turns and does not adjust. Can you just replace the bolt? If so how big of a job is it? Thanks for your responses.
MongoNv -

You should be good with the warranty claim on that '09, and that's the route you should take. I'm surprised it happened on an '09; thought they had fixed it mid-production on the '08s.

Take a look at Spec's link so that you can see what has probably failed.

Tom

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post #10 of 24 Old 08-19-2010, 10:51 PM
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Originally Posted by Tom Schmitz View Post
Spec -

Thanks for that. I learned something.

It's a good day now...

Tom

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No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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