No tools for jump starting! - 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 34 Old 01-14-2013, 02:14 AM Thread Starter
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No tools for jump starting!

Well, maybe its because the battery is three years old or maybe it's because it was 9 degrees out but either way, my battery didn't have the cranking amps to start my bike tonight. A coworker pulled up with his jumper cables just as I was discovering the stock toolkit doesn't have a ten and twelve mm socket to remove the side panels and seat. Better to learn this lesson in town than 200 miles into the desert! A new battery and more complete toolkit will be the focus this week!
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post #2 of 34 Old 01-14-2013, 08:47 AM
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Upgrading your tool kit is a worthy project. If interested, I would recommend you use this site's Search function to look for threads pertaining to tool kits to see what other riders have found handy to include in them and methods to carry them along while riding. I've gotten a lot of good "Why didn't I think of that?" ideas from the tool kit threads.



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post #3 of 34 Old 01-14-2013, 11:39 AM
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Originally Posted by PNWcrazymike View Post
Well, maybe its because the battery is three years old or maybe it's because it was 9 degrees out but either way, my battery didn't have the cranking amps to start my bike tonight. A coworker pulled up with his jumper cables just as I was discovering the stock toolkit doesn't have a ten and twelve mm socket to remove the side panels and seat. Better to learn this lesson in town than 200 miles into the desert! A new battery and more complete toolkit will be the focus this week!

One of the reasons not to bolt the seat on.

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 #4 of 34 Old 01-14-2013, 12:58 PM
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The side cover screws on my 2004 are philips head and there is a tool in the tool case to remove them. Not sure what the new gen bikes use but I would think a tool would have been provided. Seat bolts I leave off.

You should have got your friend to push you.

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post #5 of 34 Old 01-14-2013, 01:22 PM Thread Starter
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Thank you Klr4ever! You gave me a great idea for a cheep fix! The Gen II KLR's have two 10mm hex head bolts per side holding the side panels on. Because this application doesn't require much torque at all, I'm going to replace those with Phillips head screws (with a drop of blue locktite of course)

Pushing isn't an option when you're on ice.
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post #6 of 34 Old 01-14-2013, 02:27 PM
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Why not just leave the seat bolts out?




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post #7 of 34 Old 01-14-2013, 02:59 PM
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While there's certainly no reason not to replace the 10mm side panel bolts with Phillips-head screws, it also stands to reason that there are 10mm bolt heads all over the KLR so you might also consider adding at least a 10mm socket to your tool kit while you're at it.

I don't think I ever even looked in my stock tool kit. It's permanently entombed in my rear rack beneath my Action Packer.



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post #8 of 34 Old 01-14-2013, 06:14 PM
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The first bolts that went to the bin were the philips ones.....they will strip the heads after a while especially if you use loctite and we all know we must!!! If you must change them get the allen head bolts as they stay put on the end of the tool much better than a philips screw will! We drill holes directly in line with those bolts so we can remove the seat without taking the side covers off.....a much better way as long as you can live with two 3'4" holes to slide the tool in to undo the seat bolts. I'd be pretty pissed if I came out and saw my Corbin copy gone!!! Even worse if it was the original Corbin!!!

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post #9 of 34 Old 01-14-2013, 06:32 PM Thread Starter
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Yeah, I thought allens make WAY more sense than Phillips right after I posted that. I DO prefer my seat be bolted down despite the threat of the ever-present central Oregonian (nonexistent) seat-thieves. I'm modifying my seat and building a rack that will just be more sanitary if all is bolted down.

Last edited by PNWcrazymike; 01-16-2013 at 11:42 AM.
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post #10 of 34 Old 01-14-2013, 06:50 PM
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Hmmm... I thought the side panel bolts were 8mm heads and the seat was 12mm? You are correct though, there is no tool in the factory tool kit that will remove the side panel bolts on the Gen2's.

Lol, curiosity got the best of me and I had to check. The side panel bolts do have 8mm heads. Same as the side covers on the engine


Last edited by 650Stew; 01-14-2013 at 07:24 PM.
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