Swapping parts between model years - 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.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 13 Old 01-09-2016, 03:49 AM Thread Starter
Neutral
 
Join Date: Jan 2016
Location: San Francisco
Posts: 11
Question Swapping parts between model years

I'm swapping out my complete 2009 transmission with an incomplete 2014 transmission.

I would like to re-use as many parts as I can. I'm interested to find out what experiences others have had.


Here's what I've learned:

There were changes made in 2011.


Clutch:
In early 2011 the clutch was different than in later models for the same year. In late 2011 the clutch stabilized and has been the same for all KLR variants through at least 2016.
They did NOT change the shaft it mounts to or the clutch cover during 2011. This leads me to believe that the earlier model clutch may work on the later bikes. What do y'all think?


Generator:
Between 2009 and 2011 the rotor and the stator both changed, but every other part in this subsystem remains the same through at least 2014. So I'm thinking my 09 rotor & stator ought to work with the 14. What do you think?


Engine Covers:
At first inspection, the 09 engine covers seem to match the 14 case. All the holes and dowels line up. I kinda like the silver covers against the black engine. Do I need to consider anything else? Are there mechanical reasons to get later model year engine covers?
TwoFistedJustice is offline  
Sponsored Links
Advertisement
 
post #2 of 13 Old 01-09-2016, 05:46 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,228
Make sure the, "Deep Hole Syndrome" is absent/corrected.

http://www.klrforum.com/2008-klr650-...009-bikes.html
Damocles is offline  
post #3 of 13 Old 01-10-2016, 04:21 AM Thread Starter
Neutral
 
Join Date: Jan 2016
Location: San Francisco
Posts: 11
Generator Covers

After test fitting my old 09 generator cover (inside cover) to my 2014 lower end, the fit appears to be perfect. Same when fitting the 09 left cover to the 14 generator cover.

The only difference I can find between the 09 and 14 generator covers are color, and the doohickey bracket has been changed. The change doesn't affect the fit at all.
TwoFistedJustice is offline  
 
post #4 of 13 Old 01-10-2016, 06:57 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,329
Quote:
Originally Posted by TwoFistedJustice View Post
After test fitting my old 09 generator cover (inside cover) to my 2014 lower end, the fit appears to be perfect. Same when fitting the 09 left cover to the 14 generator cover.

The only difference I can find between the 09 and 14 generator covers are color, and the doohickey bracket has been changed. The change doesn't affect the fit at all.
TwoFistedJustice,
What Damocles is suggesting that you check is the depth of the 'starter reduction gear' shaft bore in the Outer Alternator/Flywheel cover.

Install both of the starter reduction gears in to the Outer cover, complete with spacer washers. Confirm that the 'upper reduction Gear Shaft' still protrudes about 10-12 mm.
Otherwise the 2008-2009 alternator/flywheel covers Need to Have a 3/8th" spacer 'slipped' into That Hole during re-assembly.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
pdwestman is offline  
post #5 of 13 Old 01-11-2016, 02:28 AM Thread Starter
Neutral
 
Join Date: Jan 2016
Location: San Francisco
Posts: 11
Quote:
Originally Posted by pdwestman View Post
TwoFistedJustice,
What Damocles is suggesting that you check is the depth of the 'starter reduction gear' shaft bore in the Outer Alternator/Flywheel cover.
No need for that on mine. My frame number is more than 5000 past the problem bikes. Also, the PO took care of all that stuff long before I ever had a chance to break it.

My bike has no remaining "stock" issues. Only user-related ones.
TwoFistedJustice is offline  
post #6 of 13 Old 01-11-2016, 02:30 AM Thread Starter
Neutral
 
Join Date: Jan 2016
Location: San Francisco
Posts: 11
Cylinder Head Bolts - changed in 2011

Getting my head refurbished by Eagle Mike. Getting my cylinder head refurbished at the same time. I'm putting in new bolts too.

One thing I noticed:

for model year 2009 the part is :"92153-1797 -- BOLT,FLANGED,10X191" and costs about $17 each.
for model years 2011 and on the part is: "92002-1874 -- BOLT, 10X191" and costs about $14 each.

I see that whererver my 2009 has a bolt with a "7" on the head, the 2014 has a bolt with a "6". In general the 2014 seems to use weaker bolts.

So I'm wondering if they take different torque specs.

For 2009 (manual: OEM 2-7) they are: 20Nm first round, and 65Nm final.

Has anyone got the torque specs for the cylinder head bolts for 2011 or later?
TwoFistedJustice is offline  
post #7 of 13 Old 01-11-2016, 08:28 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,329
Quote:
Originally Posted by TwoFistedJustice View Post


So I'm wondering if they take different torque specs.

For 2009 (manual: OEM 2-7) they are: 20Nm first round, and 65Nm final.

Has anyone got the torque specs for the cylinder head bolts for 2011 or later?
OEM Manual, 1987-2003, Final Torque- 65 N-m (6.6 kg-m, 48 ft-lb)

OEM Manual., -08 1st ed, First Torque- 20 N-m (2.0 kg-m, 15 ft-lb)
---------------------------- Final Torque- 65 N-m (6.6 kg-m, 48 ft-lb)

OEM Manual, 2008-2014, First Torque- 31 N-m (3.2 kg-m, 23 ft-lb)
---------------------------, Final Torque- 62 N-m (6.3 kg-m, 46 ft-lb)

All three manuals say Moly grease on threads and under bolt head.
As long as they are At Least 62 N-m, I'll say good to GO!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
pdwestman is offline  
post #8 of 13 Old 01-13-2016, 02:26 AM Thread Starter
Neutral
 
Join Date: Jan 2016
Location: San Francisco
Posts: 11
Moly grease moly grease moly grease. I gotta write that 1000 times with a Black Quill. Must remember moly grease.
TwoFistedJustice is offline  
post #9 of 13 Old 01-18-2016, 07:11 PM Thread Starter
Neutral
 
Join Date: Jan 2016
Location: San Francisco
Posts: 11
Mixing clutch years 2008 - 2016

Since I have a 2009 and post 2011 clutch all disassembled, I compared the measurements of of some of the small parts.

Most of the changes seem to be for adapting to the differing number of plates.

Parts that are exactly the same:
Washer 92022 (& 92022A), it's always 92022-1868
Ball bearing: 92045-1408
Collar 92143-1769
Nut 20mm 92015-1555


Parts that appear to be the same:
Spacer with the collar. The part number changes but it measures the same: 25.1 X 38 X 4

Important Differences
The clutch rod is different. They are the same total length, but the sections measure differently. The part that sticks out of the transmission shaft is 2mm longer on the 09. Which makes sense since it has to penetrate two more plates.

The RELEASE-COMP-CLUTCH is also different. Though I only have the 09, I'm guessing it changes the rotation amount to compensate for the different clutch rod.

So I think the older clutch will work on the newer KLR and vice-versa as long as you don't mix parts from different years. The release-comp-clutch will have to be the one designed for the clutch used. i.e. 2008-2011 (early) vs 2011(late) - 2016
TwoFistedJustice is offline  
post #10 of 13 Old 01-18-2016, 07:44 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,329
That makes one wonder just 'what' is going thru their collective engineering minds?

The original plate count was 7/6, changed to 8/7, now changed back to 7/6. Nuts!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
pdwestman is offline  
Sponsored Links
Advertisement
 
Reply

Tags
2009, 2014, clutch, engine covers, generator

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
swapping tires 2trax4me KLR & Other Motorcycle Related Discussion 5 07-21-2012 08:59 AM
3 years! Lockjaw The Off Topic Lounge 8 09-04-2011 01:48 PM
Two years... Lockjaw The Off Topic Lounge 20 09-10-2010 01:53 PM
KLR history- differences between a model and c model... dalahare KLR & Other Motorcycle Related Discussion 5 10-21-2006 09:33 AM
My 'C' model DaveC Show Off Your Bike 10 10-20-2006 11:30 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome