Winter Project - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 7 Old 02-01-2012, 05:35 PM Thread Starter
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Join Date: Mar 2011
Location: PA
Posts: 49
Winter Project

My winter project
I prefer to ride all winter (weather permitting). But when I had to remove the head to do some work, I decided it would be a waste not install a 685 kit while it was apart. And while waiting for the machine work to get done, do some other work on the bike. As everyone knows one thing leads to another. Schnitz Motorsports (maker of the 685 kit) recommends the ďthermo-bobĒ and PCV valve modifications. The ďthermo-bobĒ makes sense to me and for the small cost of the PCV valve, I figured why not. One thing I would like to add at this point is that when the ďthermo-bobĒ arrived, I found it to be of very high quality. The next thing I decided was while the carburetor was out, I may as well as well do the 22 cent (one washer) and Idle Screw Adjustment mods. A week or two before this all started, I had done some electrical work. I added a set of heated grips and noticed every time you add something, they want you to run the wires to the battery. I came up with a better idea. I ran a set of 12 gauge wires from the Battery (with a auto circuit breaker installed next to the battery) to a terminal strip on the front of the bike. Next I installed a six circuit fuse box under the windshield. Each of the six circuits can be set to switched or direct. Then I built a wiring harness to handle everything I planed to add. So while the bike was apart, I figured it would be a good time to finish the wiring and do the dash work I wanted to do. The dash work consisted of two parts. Rebuilding a dash that I had made before for around the ignition and a long thin dash to go in the space below the windshield. The lower dash has three outlets, a standard cigarette lighter, a USB outlet (for my phone when using for gps) and a SAE outlet. The SAE outlet can be switched to either switched or direct (for my battery tender) via a switch mounted under the fairing. The upper dash has five led lights mounted in it. One for each right and left turn signals, one for high beam, one for neutral and one for thatís a battery indicator.
Got everything together and it started first try. My lucky day. One thing I did was connect a hose to the vacuum connection on the petcock and apply a vacuum to it (just make sure you are connected to the vacuum connection) to prime the carburetor. So far itís running great. There is a noticeable difference in throttle response and seems smother. The new indicator lights high enough, that they are above my helmets chin bar, when riding upright in town. After I put some more miles on the bike I will update my findings.

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post #2 of 7 Old 02-01-2012, 08:25 PM
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Location: Brown Deer, WI
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Nice work PA_KLR.

I also have the Fuzeblock and really like the convenience of having only two wires running from the battery to the fairing. I took a different approach to mounting it though. I ran it to the right side of the fairing where the brace is, leaving enough wire to allow removing it and working on it out in the open. Didn't want to mess with removing the windshield even though that would be the ultimate spot for it. I stuffed it into a cheap waterproof bag with the bag opening at a downward angle to let any moisture out. I just insert it between the fairing and the fairing brace, loosely secure it with a zip tie and it's been functioning flawlessly for ~ 6000 miles. I met the owner of Fuzeblocks last weekend at an Adventure clinic in Milwaukee. Real nice guy.

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #3 of 7 Old 02-02-2012, 01:09 AM
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Join Date: Mar 2009
Location: NOVA
Posts: 562
Damn, I need to rewire my bike. Its a rats nest in there.

2003 Bandit 1200S
2009 KLR 650

74 Honda CB360
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post #4 of 7 Old 02-18-2012, 08:21 AM
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Location: Tucson, AZ
Posts: 37
Nice job. I like the idea of having some fused taps near the speedo area. I like the indicators up high. Kawasaki should have consulted with you when they designed this bike. I did replace the indicator with LEDs and added grip warmers (great mod).

09 KLR
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post #5 of 7 Old 02-18-2012, 10:05 AM Thread Starter
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Join Date: Mar 2011
Location: PA
Posts: 49

Got some miles on it and figured it was time for an update. But first, anyone who has a winter project and want to add it to the post, feel free to do so.

Now that Iím past the break-in period I can tell you there is a definite improvement. Seems smother, more responsive, just overall better performing. So far there has been no oil usage, but I need to log more miles before I can give a definite answer to that question. Was it worth the money? I would say yes, seeing that it used oil and the head was off. Would I tear apart a perfectly good engine to do this? The answer to that is no, Iím a firm deliver in if itís not broke donít fix it. Before the work the bike ran fine and did everything I needed it to do, now it does it just a little better. I did find that my high beam indicator is to bright. So todayís job is to add another resister to that LED.

Hope to read about some other winter projects.
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post #6 of 7 Old 03-01-2012, 09:55 AM
Join Date: Feb 2012
Location: Hydesville Calif.
Posts: 10
Nice job, my 08 was a rats nest of wiring and lighting when I bought it. I have since stripped all of the PO messs out and have only a Battery Tender pig tail coming off of the Bat. It did have a MotorCycle designed fuse unit like yours. I need to get it remounted and wired up correctly.
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post #7 of 7 Old 05-06-2012, 04:41 PM Thread Starter
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Posts: 49
Just did an oil change (over 2,000 mile) and no oil usage. It's nice not having to add oil all the time.
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