Handy spec sheet for Gen2 updated 3/18/16 - Page 6 - 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 #51 of 61 Old 06-08-2018, 01:58 PM Thread Starter
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You’re welcome! It has been a community effort.

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“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #52 of 61 Old 02-18-2019, 07:35 PM
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Mr. Schmitz, you the Man !. I an really happy you took the time and patience to edit, correct and reproduce the spec sheet. Great information . Good to know the wheel brg sizes too, since I have a few NIB sets of the 6202,6203 and 6204 brgs. (should I need to replace them on upcoming KLR). I am going to be shellfish here, but do you or know where I can get a list of all the engine/ trans bearings #s. (And) even more shellfish to ask if the bearings would show if they would be the tighter tolerance type ( letters/ numbers in the brg prefix) and open, shielded, or sealed, which I think is letters/numbers in the brg suffix. ( I don’t ask for much do I) Lol. I would be happy to buy you lunch if your ever in Deep South Texas!.

Last edited by rodent64; 02-18-2019 at 07:53 PM.
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post #53 of 61 Old 02-18-2019, 08:33 PM Thread Starter
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All the replaceable bearings are standard bearings except for the upper balancer shaft bearing. That bearing is a special-wonderful high-speed-racing custom jobbie that is made to a Kawasaki spec and no one definitively knows what is different.

The easiest place to find the bearings is in a parts fiche such as this one:

https://www.partzilla.com/catalog/ka...0e9f/crankcase

The left-side crankshaft bearing is not replaceable.

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“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 02-18-2019 at 08:38 PM.
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post #54 of 61 Old 02-19-2019, 10:27 AM
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Quote:
Originally Posted by Tom Schmitz View Post
All the replaceable bearings are standard bearings except for the upper balancer shaft bearing. That bearing is a special-wonderful high-speed-racing custom jobbie that is made to a Kawasaki spec and no one definitively knows what is different.

The easiest place to find the bearings is in a parts fiche such as this one:

https://www.partzilla.com/catalog/ka...0e9f/crankcase

The left-side crankshaft bearing is not replaceable.
Tom, do you happen to have a Gen 1 OEM service manual supplement? 99924-1080-52 or higher?
Mine is -59 / 2003 vintage

If you do, on page 4-2 of Engine right side/left side is the line drawing of the balancer system. With a Magnified View of the TOP LH rear balancer bearing. It shows the 'squared step' of the LH side of the outer race.

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post #55 of 61 Old 02-19-2019, 01:19 PM Thread Starter
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@pdwestman, I have a -58 and it does show that modification. That is very clear and is necessary to properly fit the application.

My comment, which was somewhat tongue-in-cheek, was directed more at reported conversations with a manufacturer's engineer where some very vague and non-specific comments about 'improved metallurgy' were given. The improved metallurgy resulted in 'longer life' and 'improved toughness'.

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“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #56 of 61 Old 02-19-2019, 01:24 PM
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Originally Posted by Tom Schmitz View Post
@pdwestman, I have a -58 and it does show that modification. That is very clear and is necessary to properly fit the application.

My comment, which was somewhat tongue-in-cheek, was directed more at reported conversations with a manufacturer's engineer where some very vague and non-specific comments about 'improved metallurgy' were given. The improved metallurgy resulted in 'longer life' and 'improved toughness'.
I know the conversation of which you speak.

I wonder WHY Kawasaki did Not Include the magnified view of that bearing in the Gen 2 oem service manuals?
If one uses a Magnifier and can figure out which bearing is the top LH balancer bearing in the line drawing on page 9-2 of the Gen2 manual, one can Almost see the step in that bearing.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 83,000+ miles & counting

Last edited by pdwestman; 02-19-2019 at 01:29 PM.
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post #57 of 61 Old 02-19-2019, 01:45 PM Thread Starter
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Yes, and I wonder how many have tried to replace that bearing with a standard bearing because they couldn't see the difference and assumed that, since virtually all of the other bearings are standard bearings, that the upper balancer bearing was, too.

I think it would probably bust the case. Perhaps they'd get lucky, though, with enough slop on the shaft. They'd find the error when they couldn't attach the balancer sprocket circlip. I don't know.

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“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #58 of 61 Old 02-20-2019, 04:53 PM
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Thanks for putting this together - really helpful!

For Engine cover bolts it needs to be modified to 78 INCH-lbs.
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post #59 of 61 Old 02-20-2019, 05:08 PM Thread Starter
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No, that is correct. "781NCH-bs" is a special type of torque for screws made out of cheese.

Either that or I'm just too lazy* to fix that. If I fixed that I'd be tempted to change all the 'bolts' to 'screws' because screws are threaded fasteners that clamp together two manufactured pieces where one piece is threaded, while bolts are threaded fasteners that hold two manufactured pieces together using nuts; neither of the manufactured pieces is threaded.

Yeah, let's go with the cheese-screw thing...


These things are PowerPoint charts with embedded images. They are a PITA to edit. After editing they get converted to .pdf files.

Tom [email protected]

“If I wasn't hard, I wouldn't be alive. If I couldn't ever be gentle, I wouldn't deserve to be alive.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 02-20-2019 at 05:11 PM.
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post #60 of 61 Old 02-27-2019, 10:12 PM
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Thanks! Very handy

Sounds like a lawnmower, Rides like a paint shaker!

I got 99 problems but fuel injection, 6th gear or a 2nd cylinder ain't 1!

My wife: "I didn't know if that was you coming home, or a neighbor mowing"
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