My Last Doo Question.....Hopefully - 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 4 Old 01-25-2015, 02:37 PM Thread Starter
1st Gear
Join Date: May 2013
Location: Panhandle of Texas
Posts: 66
My Last Doo Question.....Hopefully

Tomorrow is Doo Day. EM parts in hand. Getting the bike ready, drained the oil..Check, replaced oil filter..check. Oil Drain Plug and oil filter cap torqued and on..check. Removed fron sprocket cover.

Got ready to remove gear I place it in neutral or do I leave it in first gear? Thanks.

Should have added 2008, and I am doing this with the bike on the kickstand if that makes any difference.
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post #2 of 4 Old 01-25-2015, 03:38 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,615
D C,
Leave the bike in Neutral. I like to do this job, with the engine at Top Dead Center. You will be turning the engine Forward and Backwards some.
The wood-ruff key is at TDC. Use a light 'center-punch' mark on one SIDE of the KEY, (note, I said KEY! not crank!) to make it Stay in the Groove, as you put things back Together.

Also, you will find the whole job Easier, if you lean the bike to the Right, against a wall or even farther over, with RH handlebar on a Saw-horse.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 4 Old 01-25-2015, 11:25 PM Thread Starter
1st Gear
Join Date: May 2013
Location: Panhandle of Texas
Posts: 66
Thank you
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post #4 of 4 Old 01-26-2015, 11:59 AM
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Join Date: Mar 2007
Location: Fort Sask , Alberta, Canada
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Take that advice on leaning it over.

One issue, particularly when on the side stand, when the inner cover is off, and the lever spring is removed, it's possible for the adjuster shaft to slide out enough for the rear spacer washer to slip off and drop into the crankcase. Sometimes without you even realizing it. This can also happen even level or tipped but less likely. I hold my finger on the shaft so it stays in place as I remove the adjuster.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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