Might've bought a KLR.. - Kawasaki KLR 650 Forum
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post #1 of 12 Old 10-03-2012, 04:57 AM Thread Starter
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Might've bought a KLR..

Ebay is a harsh mistress..

Hi all, just signed up from Birmingham (UK)

Never ridden a trail / dual-sport bike before but fancied a bit of a change and had been looking for a KLR650 for a while, got tempted in by an auction last week but I'm a bit confused as to what exactly I've bought and wondering if anyone can help pick the bits out of this!

I've uploaded some photos to an Imgur photo sharing album here: imgur.com/a/sdPsQ#0 if anyone has some time to look through?

What I know is that the v5/logbook lists it as a KLR650A1 registered in February 1988, the frame and engine numbers match to the logbook and the frame number starts with "KLR650..."

I can tell that the fairings and tank are from a klr600 with an aftermarket front mudguard but there are a few things that seem odd to me:

- the water system, it has two radiators with an electric fan on the right-hand side, I was expecting a coolant bottle on the right with the fan on the left?

- the frame has the single bolt hole for the klr600 tank

- the rear sub-frame is made out of square section tube (klr600?)

- there appears to be an extra loop in the water system, from a round stainless steel block fitted over the thermostat housing the pipe looks back through the clear bubble then goes into the water pump housing as a small bore pipe in between the two main water pipes?

- it's running a moto style 17inch front wheel with a larger than standard disc and a twin-pot caliper that the PO said he thought was off a zx600

I think it looks pretty awesome to be honest and with a bit of luck I might be able to get it through an MOT if i can re-seal the leaky 600 fuel tank and shell out for some new tyres.

Longer term I was hoping to fit a 6Gallon IMS tank which is what started the confusion, all the youtube vids and pictures I've seen of early klr650s have the tank mounting with two bolts at the back.. are these bolt holes on the rear subframe? if so could i replace the subframe with a later one to fit the big tank? and would that mean replacing the fairings with 650 ones to fit?

sorry for dumping this all into a 1st post, I'm just massively confused right now!
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post #2 of 12 Old 10-03-2012, 07:54 AM
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Welcome aboard. I'm going to suggest that you use Google for a bit. You definitely seem to have a KLR 600.

I did a quick Google search and found this info about the cooling system.

Quote:
In design, the Kawasaki's cooling system is just like those used in recent moto-cross engines. There are two small radiators mounted in front of and just below the gas tank, and the coolant, a recommended 57/43-percent mix of water and anti-freeze, flows from the rightside-mounted water pump to the cylinder head. From there, coolant is pumped through a thermostat to the right radiator, behind which is mounted a small, eight-bladed fan to help out when things get really hot. The coolant then crosses the frame to the second-stage radiator and is routed via a rubber hose back to the pump. Black, cowcatcher-style air shrouds made of plastic direct air through the radiators.
.

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post #3 of 12 Old 10-05-2012, 07:09 AM Thread Starter
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Hi klr4evr, thanks for the welcome and the response

I've been googling myself and you're quite right, the water system is standard klr600 stuff, it's just odd that what I'm turning up on the internet keep coming back as a 650.. So far I've found:

- the UK DVLA (vehicle registration and road tax) system reports the numberplate as KL650-A1, 651cc, Feb 1988

- the V5 (uk vehicle ID paperwork) has the correct frame & engine numbers for the bike (frame: KL650a-008xxx - am obscuring the last three just in case!), as far as I know in the UK you can change legally change the engine number to match a replacement engine but I don't think you can alter the frame number?

- online insurers are returning the bike details as: "1988E Kawasaki Klr 650 Trail 651CC Petrol"

To be honest I'm not that fussed if it actually is a 600, it still looks cool to me, the only spanner it may throw in the works is with tank range, I was hoping to chuck an IMS tank on aiming for ~275 miles between refills that would allow me to either do all my week's commuting on one tank, and have a good range for longer journeys - I currently ride a GPz900 that gets 130 miles to a tank and it's just too short a range for daily use

Is there anywhere online that lists out eh frame or engine numbers for models and years?
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post #4 of 12 Old 10-05-2012, 10:07 AM
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It's an A1? I thought UK bikes were Cx.

Can you look at the base of the cylinder and see what is embossed on the cylinder base for displacement?

Wonder if it is a frankenbike imported from the US....

T

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Last edited by Tom Schmitz; 10-05-2012 at 11:45 AM.
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post #5 of 12 Old 10-08-2012, 04:38 AM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
It's an A1? I thought UK bikes were Cx.

Can you look at the base of the cylinder and see what is embossed on the cylinder base for displacement?

Wonder if it is a frankenbike imported from the US....

T
Well, some of it might be an A1! It's definitely a frankenbike, previous owner bought it in boxes from an auto-jumble several years ago and I'm fairly sure that some of the boxes might just have been from a different bike

Had another look at the engine and it has "0651" and the loop letter like a lower-case L on the left-hand side of the cylinder block, also the clutch cover has the form at the back for the kick-starter handle but it's blanked off / not been pressed out.

As far as I can tell, the radiators (water system), tank, fairings, seat and rear sub-frame are KLR600, the main frame seems to check back through the DVLA / UK insurance databases as a 650, the engine says it's a 650 (though as my father is fond of saying "it says Bisto on buses but you can't get gravy off t'Conductor").

Both wheels are 17inch, I think the rear is standard 650 (3.5inch x 17inch?), the PO said the front is a 650 hub with KTM spokes onto a 17inch rim with an odd size tyre (100mm / 80mm x 17inch), might see if I can get a more normal 120/70x17incher to fit though.

I Sorted the wiring out over the weekend so I now have working indicators and a brake light that doesn't flash along with them, and have ordered in some Petseal to see if I can salvage the leaky tank so I'm hopeful of getting an MOT done soon

One question I have though, can anyone tell me if the mounting points for the front of the side panels and the back of the fuel tank on a 650 are on the rear sub-frame? Once I've got it road-legal I'm tempted to try to switch it over to early 650 bodywork as I prefer the shape
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post #6 of 12 Old 10-08-2012, 10:41 AM
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tenkasen -

It's starting to sound like a pretty neat franken-supermoto! A blend of KLR600 and KLR650, with a bit of SM thrown in.


In this photo you can see both the tank mounting points (two holes either side of the big hole on the cross-member on the sub-frame) and where the forward panels are tied down.



T

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #7 of 12 Old 10-08-2012, 10:52 AM
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Sorry to hijack this thread but Tom, in that pic thewre is a small "L" shaped hose coming from the airbox ahead of the screen with an enlarged end to it....what is this for? I have never seen one with this hose on yet...it has the 08 and up fuse pack from what I can tell....any ideas?

Sorry to hijack....back to the regularly scheduled program.....

OH.. welcome from a fellow Brit...now living in Canada. Sounds like you have a good project to play with there....enjoy.

Willys
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post #8 of 12 Old 10-08-2012, 11:07 AM
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willys -

That's part of the evaporative emissions control system. There is normally a hose there that goes back to the canister. After I removed the evap stuff I put a plug in that elbow to block it off. It's an '08.

T

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #9 of 12 Old 10-11-2012, 05:28 AM Thread Starter
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Tom, thanks for the photo that does help a little! The rear sub-frame on my bike is totally different to that one being made out of square section tubing and completely missing the forward cross link with the big hole & the tank mounts.

From what I can see, the 600 tank is much much shorter than the 650, bolting into the top of the main frame rather than onto those sub-frame mounts.. the Petseal gunk I ordered has turned up this week so I'll be getting mucky in the garage in an effort to save the leaky 600 tank, failing that I'll look into a 650 rear end and tank I think

I think I've identified the exhaust end can as one off a Honda crf450 also, had the engine running briefly and it's just on that border line between "damn that's loud!" and "WHAT?".. should be perfect for filtering in town
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post #10 of 12 Old 10-11-2012, 06:59 AM
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welcome tenkasen - your bike sounds like an interesting find... but shsshhhhh don't use the "filtering" word ... but maybe it passed by unnoticed... shhh....
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