got my new 08 - 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 10 Old 07-24-2008, 08:03 AM Thread Starter
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got my new 08

Picked it up last night and had to truck it home. we'll I haven't rode in 25 years so I'm taking it easy. Got it off loaded this morning using the loading ramp at work and comming down the ramp I hear a squeeking sound every time I turn the handlebars..left or right. I'm thinking new bushings a little wear and it'll be ok.

well after about 5 min of riding on the grass at work I'm liking the bike I feel like I never stopped riding...life is good. I park it and go in to work. I'm happy.


All the guys from work are checking it out and My chest is pumped out a bit if ya know what I'm saying. Cem, a biker for a while said" dude the steering is way too stiff" so we get to looking... seems the idiot who assembled the bike screwed up! The clutch cable was not run thru the cable guide near the clutch on the handlebars where it passes down thru the tank assembly, when it went down towards the frame it was run under the ignition box and was pinching between the wires comming out of the ignition and the frame . Dude to say I was pizzed was an understatement. I got less then 1 mile on the bike and I'm already wrenching. Then we noticed the speedo cable comming off the front wheel was not run thru the cable guide on the front fender..fixed that.


Not a great way to start I'll tell ya...

But aside from that I can't wait to get off work and do some riding and break her in some.

I'm gonna call the dealer and let him know about that crap assembly man he has. Had that clutch cable pinched hard....it could have been ugly!!!
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post #2 of 10 Old 07-24-2008, 11:42 AM
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, just another dealer screw up to add to the long list of others. Glad you caught the issue. That is why is so good to just be able to do your own wrenching. YOU know it is done right. Ride and Enjoy ...
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post #3 of 10 Old 07-24-2008, 12:54 PM
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Chek yo mufler bolts fo sho den.
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post #4 of 10 Old 07-24-2008, 01:26 PM
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Check all bolts. You might as well pull as many as you can and put some blue Loctite (a very little will do). Not really wrenching - just call it "familiarization".
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post #5 of 10 Old 07-24-2008, 02:34 PM Thread Starter
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Thanks guys.On the muffler bolts, which ones were they haveing the problems with?


Well on a lighter note 30 mins and I'm off work I get to finally go test her out!!!!!!!!!!!!!!!!!!
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post #6 of 10 Old 07-24-2008, 03:00 PM
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Originally Posted by Capt stan View Post
Thanks guys.On the muffler bolts, which ones were they haveing the problems with?
out!!!!!!!!!!!!!!!!!!
I would guess the ones falling out.

Like BIGIRON said, check them all. Enjoy you ride.
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post #7 of 10 Old 07-24-2008, 06:42 PM
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The rear most bolts back under the rear deck. There should be two. Also the clamp bolt mid pipe has a tendency to just fall out. Mine was gone two months after I bought it. Luckily the pipe didn't seperate. BigIron is right, you need to blue loc-tite every nut and bolt you can remove.
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post #8 of 10 Old 07-24-2008, 08:06 PM Thread Starter
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The rear most bolts back under the rear deck. There should be two. Also the clamp bolt mid pipe has a tendency to just fall out. Mine was gone two months after I bought it. Luckily the pipe didn't seperate. BigIron is right, you need to blue loc-tite every nut and bolt you can remove.
OK thanks for the info.

I got 73 miles on her tonight and some rain time to boot. I was impressed how smooth it was. I thought there would be more vibration, seems to be good smooth power and I really like the brakes on it. I think I'm gonna like this one!!

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post #9 of 10 Old 07-25-2008, 04:20 AM
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Talking

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Originally Posted by DXKLR View Post
Also the clamp bolt mid pipe has a tendency to just fall out. Mine was gone two months after I bought it. Luckily the pipe didn't seperate. BigIron is right, you need to blue loc-tite every nut and bolt you can remove.
Congratulations! Itís a KLR!!!!

My clamp came off and was just hanging there earlier this spring. Bolt stayed in though. Since then I just randomly check bolts about once a week. I havenít found anther loose one yet. I do hear what I think is the heat shield on the muffler pipe pinging. They have rubber washers so Iím not sure if I should tighten them down too much.
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post #10 of 10 Old 07-25-2008, 08:01 AM
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We took the rubber washers off, and installed regular bolts to hold the heat shield on with. The philips screws get set by the heat and don't want to come out unless you use vicegrips. Snugged them up tight, no more metallic pinging. .... might not be the right thing to do, but I hate pinging.
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