New Owner needs a punch list - 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 26 Old 10-16-2010, 10:02 AM Thread Starter
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Join Date: Oct 2010
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New Owner needs a punch list

What MUST be done?
I have a 02 w/ 25k I just got. I know the Doohicky must be visually inspected to make sure it has been replaced..(25k?)
What else?
What to watch for? I have come across things that I thought would be outlined in a sticky but perhaps I missed a list.
Some oil ring replacement?
Thanks and howdy!
cw
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post #2 of 26 Old 10-16-2010, 10:46 AM
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Hi seaweaver, welcome. So you just got a bike with 25k on it, and want to know what you have to work with. You already know what you need to do for the balancer system / doohickey.

I guess I would start with fluids. Fresh oil and filter. These bikes share the engine oil with the transmission. The oil takes a beating, and requires more frequent changing than engines that have their own oil sump. Most feel 2,000 miles is stretching it. We also have a wet clutch, which means we need to avoid Energy Conserving oils. They have friction modifiers that could render your clutch useless.

I'd check the cooling system. Make sure the fan is kicking on. Locate the relay fuse. Take a peak at the coolant level and condition.

Fork oil. I'd change it. Find out what you have for fork springs in there. Fork oil gets contaminated. You can adjust the fork dive with oil and air.

Fasteners. I'd be looking over every bolt on the bike ESPECIALLY frame bolts. Some are known to shear. Usually this is from allowing them to loosen up. These bikes have a tendency to loose fasteners. We have to stay on top of that. Blue Locktite is your friend.

Check your battery. Pull the terminals off and clean them, check the battery fluid level. Some bikes will suck water out of the battery like crazy. I use a sealed battery, so not an issue. I do clean my battery terminals about every 90 days. Walking = unhappy.

Brake fluid. I change mine every year. Brake fluid will become contaminated and no longer performed as designed. This will effect your ability to stop. Stopping on demand is a high priority for me. Not optional, you'd say.

We have tube type tires. They have a tendency to leak down a bit. To get all the life out tires you can get, we gotta stay on top of air pressures.

Air filter. Clean it often. You can buy a filter specific oil or use engine oil. Just do it frequently.

Fuses can be an issue. You might want to locate them and have a few replacements.

Chain and sprockets. You need to stay on top of these. A chain that breaks can take out your engine case, butcher your ankle or wrap around the swing arm, locking up the wheel and sliding you down the road. Ask if you need information on what to look for.

That's a start, giving you a fresh start and a point of reference for future maintenance intervals. Get your post count up so you can post some pictures of the bike. We can tell by looking whether some modifications have been done or not, or point out to you if something might need attention.

And please ask questions. We have competitive helpfulness here. We base out arrogance on who gets there first with the most information.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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post #3 of 26 Old 10-16-2010, 11:44 AM Thread Starter
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Quote:
Originally Posted by vatrader View Post
Hi seaweaver, welcome. So you just got a bike with 25k on it, and want to know what you have to work with. You already know what you need to do for the balancer system / doohickey.

I guess I would start with fluids. Fresh oil and filter. These bikes share the engine oil with the transmission. The oil takes a beating, and requires more frequent changing than engines that have their own oil sump. Most feel 2,000 miles is stretching it. We also have a wet clutch, which means we need to avoid Energy Conserving oils. They have friction modifiers that could render your clutch useless.

I'd check the cooling system. Make sure the fan is kicking on. Locate the relay fuse. Take a peak at the coolant level and condition.

Fork oil. I'd change it. Find out what you have for fork springs in there. Fork oil gets contaminated. You can adjust the fork dive with oil and air.

Fasteners. I'd be looking over every bolt on the bike ESPECIALLY frame bolts. Some are known to shear. Usually this is from allowing them to loosen up. These bikes have a tendency to loose fasteners. We have to stay on top of that. Blue Locktite is your friend.

Check your battery. Pull the terminals off and clean them, check the battery fluid level. Some bikes will suck water out of the battery like crazy. I use a sealed battery, so not an issue. I do clean my battery terminals about every 90 days. Walking = unhappy.

Brake fluid. I change mine every year. Brake fluid will become contaminated and no longer performed as designed. This will effect your ability to stop. Stopping on demand is a high priority for me. Not optional, you'd say.

We have tube type tires. They have a tendency to leak down a bit. To get all the life out tires you can get, we gotta stay on top of air pressures.

Air filter. Clean it often. You can buy a filter specific oil or use engine oil. Just do it frequently.

Fuses can be an issue. You might want to locate them and have a few replacements.

Chain and sprockets. You need to stay on top of these. A chain that breaks can take out your engine case, butcher your ankle or wrap around the swing arm, locking up the wheel and sliding you down the road. Ask if you need information on what to look for.

That's a start, giving you a fresh start and a point of reference for future maintenance intervals. Get your post count up so you can post some pictures of the bike. We can tell by looking whether some modifications have been done or not, or point out to you if something might need attention.

And please ask questions. We have competitive helpfulness here. We base out arrogance on who gets there first with the most information.
Yep...That the kind of list I was looking for!
I just rode over to my brothers house to borrow a tool and he was looking the bike over and found something disturbing. The rear sprocket is lose, wobbly and appears at one time so bad that a sprocket bolt cut a notch into the rear arm. I'm going to park the bike till I can get that ( and a lift from Harbor fright) fixed. The previous owner gave me a manual on disk that I need to get opened and sort out some of these things you have mentioned.
Thanks.
cw
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post #4 of 26 Old 10-16-2010, 12:03 PM
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Location: Virginia
Posts: 1,263
The rear sprocket will have a bit of play, maybe a quarter inch. It has a rubber damper / bushing between the sprocket and the hub. Here is a diagram of the rear hub;

http://www.bikebandit.com/houseofmot...50-a18/o/m3692

You might check that the spacers are on the axle in the right ordwer and location. It is easy to get them mixed up, which might give you some play where there shouldn't be any.

Not too sure about the sprocket bolt / swing arm notch thing. Pictures. Got a host site for photos, like photo bucket? I'd like to see this.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
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post #5 of 26 Old 10-16-2010, 12:54 PM Thread Starter
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flip...it seems i cannot get you any link from PB as well till 15 posts....sooooo! her we go!
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post #6 of 26 Old 10-16-2010, 12:54 PM Thread Starter
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.....4
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post #7 of 26 Old 10-16-2010, 12:55 PM Thread Starter
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........5
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post #8 of 26 Old 10-16-2010, 12:56 PM Thread Starter
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.........6
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post #9 of 26 Old 10-16-2010, 12:59 PM Thread Starter
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.....7
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post #10 of 26 Old 10-16-2010, 12:59 PM Thread Starter
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......8
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