Fairing installation - 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 15 Old 04-22-2019, 08:26 PM Thread Starter
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Fairing installation

I am sure this has been covered somewhere already, but I have yet to find it. I looked at a couple of youtube videos and the Partzilla fiche and nothing shows the detail I need of the upper left side fairing. When I removed mine to do the Thermo-Bob installation, the well nut in the front inside fell out. This is the one the holds the upper part of the radiator guard.

Apparently, it was never installed correctly at the factory and I am hoping it may be the source of the buzz I’ve had in the fairing since the bike was new. I assume this well nut gets pushed through the fairing hole from the front and then I assume the fairing and well nut go behind the bracket at the top of the radiator and then the radiator guard goes on the front with the bolt then going through to sandwich the radiator bracket between the radiator guard and the fairing well nut. Is this the correct way to install this well nut? The picture shows how I think it goes, but wanted to check here before I pop it into the hole.

The right side fairing well nut did not fall out, but had been out in crooked and then tightened down and is now rather distorted and will not stay in the fairing hole. Probably should get a new one for that side.

Picture was rotated 90 degrees CCW during the upload. What is facing up now really is the forward direction of the left side fairing.
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Last edited by Voyager; 04-22-2019 at 08:28 PM.
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post #2 of 15 Old 04-23-2019, 05:47 PM
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I think you have it correct there. You would push it through (I'd screw the bolt in and push that, so the rubber stretches as it goes in) and then when you tighten it, the bolt will be pulled toward the flat flange, pressing the rubber out behind the fairing surface and pulling everything tight.

Regarding the buzzing, I wanted to mention that I created a post about this a while back. I'm not sure if it's the same with your bike, but with mine this was coming from the joint between the side and middle fairings. Just last weekend I finally got around to disassembling the front fairings, and creating rubber gaskets to line the joints where the side panels lay against the middle. The buzzing is now gone.

I made the patterns by getting them right on paper first, then cutting pieces from 1/64" sheet rubber (eBay). I'll post the patterns to my original post soon, so you wouldn't need to mess around with that process if you wanted to silence this. In the next few days you'll find a link here:

https://www.klrforum.com/2008-klr650...-cowlings.html

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post #3 of 15 Old 04-23-2019, 06:23 PM Thread Starter
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Quote:
Originally Posted by samuel View Post
I think you have it correct there. You would push it through (I'd screw the bolt in and push that, so the rubber stretches as it goes in) and then when you tighten it, the bolt will be pulled toward the flat flange, pressing the rubber out behind the fairing surface and pulling everything tight.

Regarding the buzzing, I wanted to mention that I created a post about this a while back. I'm not sure if it's the same with your bike, but with mine this was coming from the joint between the side and middle fairings. Just last weekend I finally got around to disassembling the front fairings, and creating rubber gaskets to line the joints where the side panels lay against the middle. The buzzing is now gone.

I made the patterns by getting them right on paper first, then cutting pieces from 1/64" sheet rubber (eBay). I'll post the patterns to my original post soon, so you wouldn't need to mess around with that process if you wanted to silence this. In the next few days you'll find a link here:

https://www.klrforum.com/2008-klr650...-cowlings.html
That was my assumption, but I figured it prudent to check in here. I am surprised it fell out and am guessing it wasn’t inserted properly at the outset. The one in the same position on the right side was clearly put in cockeyed and then tightened that way as it is pretty severely distorted.

As to the noise dampers, did you buy self-adhesive rubber sheet? Or just tuck in place and tighten the screws?

I am thinking of replacing the oil line banjos with the ones that pdwestman listed somewhere (got to find that post) to try to get more oil to the top end and less to the crank. If I order those, then I will add on one or two of these well nuts as I will be paying shipping already so adding on a cheap part isn’t so painful.

On that topic, are there any favorite suppliers for Kawasaki parts? I have used Partzilla and Bike Bandit in the past for parts for my Polaris ATV, but haven’t bought Kawasaki parts in nearly 20 years.
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post #4 of 15 Old 04-23-2019, 07:39 PM
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The part numbers for banjo bolts and how to modify the ones you have can be found here: https://www.souperdoo.com/stuff%20th...ht-oil-burning

I use Partzilla almost exclusively. Their prices are decent, their order system is good, shipping is reasonable and quick, and their customer service excellent. I think the benchmark of a company is that you never get to find out if their customer service department is any good, but I have had two occasions with Partzilla. They were very competent and responsive.

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post #5 of 15 Old 04-23-2019, 07:40 PM
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I had the bottom one on the other side fail the last time I put the fairing back on… I think they're kind of weak, and I've got 'em in my Partzilla cart as well.

As for other sites, I've seen Paul talk about this one, but I don't know of any others where you can order parts from microfiche (I'd be interested to learn some new ones tho). Also, this one seems more expensive that partzilla:

https://www.kawasakipartshouse.com/

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post #6 of 15 Old 04-23-2019, 08:15 PM
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Quote:
Originally Posted by samuel View Post
I had the bottom one on the other side fail the last time I put the fairing back on… I think they're kind of weak, and I've got 'em in my Partzilla cart as well.

As for other sites, I've seen Paul talk about this one, but I don't know of any others where you can order parts from microfiche (I'd be interested to learn some new ones tho). Also, this one seems more expensive that partzilla:

https://www.kawasakipartshouse.com/
The primary reason that I have linked to the Babbits kawasakipartshouse numerous times, is because of its format and also their part# SEARCH feature in the Lower RH corner.

RMATV/MC does not have the search feature. kawasakipartshouse barely goes back to 1987.
I've never ordered from partzilla, maybe I ought to compare?

ps, As a former Kawasaki Dealer, I try to encourage people to Support their local dealership or Independant Service Facility when ever possible. Without their presents in your area it may become an even longer drive to get truly needed assistance for Real Problems.
UPS, Fed EX and others are getting rich as the Brick & Mortar, mom & pop stores are closing.

pdwestman
Modify at "YOUR OWN RISK"!

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

Last edited by pdwestman; 04-23-2019 at 08:28 PM. Reason: ps added
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post #7 of 15 Old 04-24-2019, 08:50 AM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
The primary reason that I have linked to the Babbits kawasakipartshouse numerous times, is because of its format and also their part# SEARCH feature in the Lower RH corner.

RMATV/MC does not have the search feature. kawasakipartshouse barely goes back to 1987.
I've never ordered from partzilla, maybe I ought to compare?

ps, As a former Kawasaki Dealer, I try to encourage people to Support their local dealership or Independant Service Facility when ever possible. Without their presents in your area it may become an even longer drive to get truly needed assistance for Real Problems.
UPS, Fed EX and others are getting rich as the Brick & Mortar, mom & pop stores are closing.
I agree and do the same, but my dealer is 67 miles away so it isn’t convenient to go there for a $5 part. Well, there is a dealer closer by, about 30 miles, but they jerked me around so much when I was trying to buy my KLR last year that I went to the one 67 miles away to make the purchase. The closest dealer acted like they didn’t care if I bought a KLR or not. So I didn’t, at least not from them. They had two in the crate and after two phone calls and two visits over the course of a month they could not even be bothered to assemble one for a test ride. So, I definitely won’t give them any parts or service business.

I also like the videos that John Talley (SP?) at Partzilla makes. He is one of the better techs on youtube - always very technically accurate. And his video presence is comparable to Tim2Wheels. He doesn’t specialize in any one brand of bike or ATV, but he has done a few videos on a few basic KLR maintenance items.
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post #8 of 15 Old 04-24-2019, 02:45 PM
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Quote:
Originally Posted by pdwestman View Post
The primary reason that I have linked to the Babbits kawasakipartshouse numerous times, is because of its format and also their part# SEARCH feature in the Lower RH corner.

RMATV/MC does not have the search feature. kawasakipartshouse barely goes back to 1987.
I've never ordered from partzilla, maybe I ought to compare?

ps, As a former Kawasaki Dealer, I try to encourage people to Support their local dealership or Independant Service Facility when ever possible. Without their presents in your area it may become an even longer drive to get truly needed assistance for Real Problems.
UPS, Fed EX and others are getting rich as the Brick & Mortar, mom & pop stores are closing.
I hope I didn't come across as knocking the kawasakipartshouse site. I check it regularly, and it's good to know they have a part# search. I haven't explored the local dealer option yet. Perhaps I should…

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post #9 of 15 Old 04-24-2019, 04:43 PM Thread Starter
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Can someone help me ensure I have the correct part number for the rubber well nut that is used on the upper inside bolt on the side fairings? The parts diagrams at both Partzilla and Bike Bandit seem to indicate that this is part number 90215A which is just described as a nut. However, the description for part number 90215 seems more like what I have now which says nut, rubber, 6mm.
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post #10 of 15 Old 04-24-2019, 04:51 PM
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92015A looks like the correct part. There are more than one type of these wellnuts, and the PZ page for the part itself shows it as being rubber:

https://www.partzilla.com/product/ka...6044081bd91ab2

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