...Anything less than 3000 to me is lugging it. Mine seems to run best between 3000 and 6 - 6500 anything more and it tapers off fast....
I agree with flash here. I don't like to run it much under 3500 as it seems "luggy".
First gear on the KLR is stupid-tall. The 1-2 shift drops 1500 rpm, so shifting at 5000 puts me in second at 3500 and feels right.
All the other shifts drop about 1000 rpm, so shifting at 4500 puts me in the 3500 range, and I move up to 4000 which I find coincides with many speed limits with stock gearing.
Normal operating range, then, is 3500 to 5500, though it has seen 8000 rpm. Booyah!
If yours sounds like it wants to explode (and it's not 'just you'
) perhaps your balancer chain needs to be adjusted.
Pop the little rubber cover off the lower left side of the case and get an 8mm socket on the bolt. Turn it out one turn. Rap on the head of the ratchet handle with a screwdriver handle to help jiggle things a bit (that lets the lever move and adjust the chain). Then turn the handle back one turn to torque things back up. Understand, that bolt doesn't need, nor can the doo stand, a lot of torque. Just snug is all it needs to be.
If the engine is not noticeably quieter after that (and it's not 'just you') then you may have a doo spring that has given up and is not tensioning the lever. Very common on the Gen2s, and indicative of a need to dive in there and do the doo.
Gas mileage - I slab in at about 240 and pretty regularly turn in 47 mpg +/- 2.
...the speed which the manual recomends shifting when I'm at or around 3000 rpms.
/requisite smart ass comment mode on/
The manual also talks about the sixth gear, which I have never been able to find...