Crunched K - Some thoughts/help req'd - 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 5 Old 08-09-2016, 09:20 PM Thread Starter
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Crunched K - Some thoughts/help req'd

The story is - I bought a 2009 without thinking through it all...saw the bent handle bars and thought that was it, WRONG! After taking the fairings off, the rad looked like a potato chip. Replaced the rad and the LH fairing wouldn't fit, it's like its worst now than it was. Setting on the bike I notice that the gauge pod is slightly off center, just barely but enough so I order a new support. Just put it on and thought that would be my save all for all this, NOT! Now the right hand fairing won't fit at the bottom.

I'm thinking I need to replace the frames that hold the rad and/or the overflow tank? But it looked like the rad fits on the frame? I don't have a good picture of all the bits, like an exploded view, like I'm going to have the real thing here in a few days if all this doesn't start fitting. Blowing it up sounds good at this point, just really disappointed but I'm still hopeful that somewhere here might help me.

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post #2 of 5 Old 08-10-2016, 08:07 AM
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I have a couple thoughts, based on my 2016 model. First, the left side panel is sort of difficult to reinstall to begin with, literally to the point of frustrating! You may be experiencing a little of that. Second, potatochipification of the rad occurs because the flimsy (but expensive) rad is all that holds up the 450 pound bike in a left fall; get crash guards. Third, when a motorcycle falls or crashes (either side) sometimes things bend and sometimes things just go out of wonk. Obviously you need a new bar to replace the one that bent. However, before you start replacing other parts that you're not sure are damaged, there's a process for truing up your alignments that simply went wonky. Essentially, it's a process of loosening up nuts and bolts and eyeballing that everything goes back to square and then tightening everything. Easier to do if you have a lift. Your dealer service department is probably better at it.

I can't count the times my KLR has been on its sides. I even had one of my crash guards break. I've had a couple times where my front wheel/fender were pointed off into the wrong direction relative to the nose cone. I don't have a lift, but my son and I have been able to get them realigned. I haven't had a problem with the gauge cluster or nose cone, but my recollection being under there is that there's a lot of nuts and bolts that could be the culprit.

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post #3 of 5 Old 08-10-2016, 11:18 AM
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Originally Posted by Bill10 View Post
Bill why are you laying on the ground? you look like you feel off a bike, but I can not see on, kidding, great phone btw.

I would try a true up the bike before buying replacement parts. How much did you get the bike for?
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post #4 of 5 Old 08-12-2016, 07:40 AM
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Which brings up another reason to get crash guards. Last April I bought a DR650 so I'd have two dual sports so my son and I could go riding. The DR doesn't need all the protective crap, like crash guards, that the KLR does. So by mid May I was in rolling through deep sand on forest road in the Richloam WMA and lost the rear; fell right. Twisted knee, MCL tear, eight weeks to riding, still not right. Yeah, if I was on the KLR that probably wouldn't have happened. Maybe, but probably not.
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post #5 of 5 Old 09-06-2016, 04:55 AM
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I guess I have been lucky. Or at least lucky for a person who has had this bike down 4X with no major damage. The only time it actually got damaged was whenever it fell over just sitting there when the kickstand sink into the ground. My main problem is riding on quad trails and trying to switch from one track to the other. The first time it happened the bike and I came to rest in about 6 inches of water and 6 inches of mud. The bike was undamaged until I walked over to it to grab the handlebars to pick it up and I stepped on the mirror... crunch. So far I have not done any damage that zip ties and mighty putty could not fix LOL. I must say I never felt so young again as when I was picking myself up out of the mud

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