Kawasaki KLR 650 Forum - Reply to Topic
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

Thread: 1986 KLR600 STOLEN...rebuild thread Reply to Thread
Title:
Message:
Trackback:
Send Trackbacks to (Separate multiple URLs with spaces) :
Post Icons
You may choose an icon for your message from the following list:
 

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










  Additional Options
Miscellaneous Options

  Topic Review (Newest First)
04-30-2018 02:34 PM
joepoko ended up going with the pro-tapers, they're showing up in the mail today, hopefully our mail thief who took my girlfriend's packages last week isn't in the market for new handlebars...

i keep popping a 20A fuse when I rip up and down the street on the bike. The battery is over a year old, and I'll be honest i haven't been letting the bike fully warm up before revving it and riding it. Should i replace my battery and be more patient or do you guys think i've got a short somewhere?

04-25-2018 10:58 AM
joepoko alright lads, we're almost there.



turn signals, covers, skid plate, etc all mounted back on. battery charged up (new one is on the way but this one still holds a charge), new fuses in, clutch adjusted to a good tightness.





chillin' time. little bit of ding repair on a P.O.S. surfboard. Made friends with the neighbors and hung out out front and shot the shit for a little bit.



still looking for good input on renthal bend that goes well with stock. is there anything online that has the stock dim's for the KLR600 handlebars? i saw a couple of you mentioned earlier the pro taper RC or ATV Highs. ATV High's look on point.

Headed to DMV tomorrow to re-register so I can ride this baby on the street and really see how she's doing.
03-29-2018 03:48 PM
pdwestman Wasn't Loc-Tited by the factory. And you didn't buy it brand new, so,,,,,,,,,,,,,,,,

An oxy/acetylene torch with a small welding tip to quickly heat the nut only is best bet. Does that mounting bolt also serve as lower suspension pivot mount?

Even if it don't, it would be good to be removed and re-grease bolts & suspension bearings.
03-29-2018 03:19 PM
joepoko so i went to work on my footpeg replacement last night and it turned out to be way more of a headache than i could handle.





is there loc-tite or something on this screw when it comes out of the factory? its in there real, real, real good and i could not break it out.

took advantage of this time to clean up the side panels though...starting to look like my bike again...





and that's it for now...bashed my shin skating earlier in the day and ended up calling it early last night.
03-19-2018 07:23 PM
Tom Schmitz It's been a long row to hoe; I'm glad to see it back together.

Ya done good.
03-19-2018 03:10 PM
joepoko after an hour of trying to salvage the front of my left hand control by incessantly beating the back end of it to get the top screw out, i gave up and replaced the whole assembly with the one i got from ebay, where the only difference is that the words have faded off the control. no biggie.





slapped the exhaust back on. but you should have seen me when i was an excited little idiot and tried to kick over the bike a few times with no header or muffler on the bike. looks "not bad." gotta slap the other side covers on to really complete the look.





and time to take her for a spin...


she moves! clutch feels like it needs adjusting though, the bike doesn't really engage until the clutch has been completely let out. but otherwise, sounds like the KLR and feels like her too! STOKED.
03-16-2018 03:16 PM
joepoko
Quote:
Originally Posted by pdwestman View Post
Unless one used anti-seize grease on the exhaust heat shield screws 30 or 3 years ago, I'll suggest you best leave them alone. They will ALL be rusted in, you will mangle most or all of them and it's not worth it.

If you drill the head off of the LH switch case screw you may use a small Vise-Grip to remove the shank after the assembly is separated off of the bar.

Who removed the oil injection pump & tank from the DT400? Those parts were very reliable on the Yamaha YL-1 & CT-1 that my brother & I rode back in our early days.
yep, no luck on two of the heat shields. got the others off with visegrips. i'll take it.

dt400 oil injection pump is still on there, just disconnected.


alrighty, so.

exhaust is off. i fell on my ass skating earlier that day so crawling around on the ground getting the header off was a lot of fun.





after a little cleanup...



and some paint! a little less like a rust bucket!



luckily last night while i did this it was a nice night and i rode my bicycle over to the garage. hung out for a little bit and stared a little more at the fleet. spring cleaning coming soon...

03-13-2018 06:53 PM
pdwestman Unless one used anti-seize grease on the exhaust heat shield screws 30 or 3 years ago, I'll suggest you best leave them alone. They will ALL be rusted in, you will mangle most or all of them and it's not worth it.

If you drill the head off of the LH switch case screw you may use a small Vise-Grip to remove the shank after the assembly is separated off of the bar.

Who removed the oil injection pump & tank from the DT400? Those parts were very reliable on the Yamaha YL-1 & CT-1 that my brother & I rode back in our early days.
03-13-2018 03:25 PM
joepoko couple more small not all that insane developments....

new brake lever.



new taillight lens (being held in by only one screw since the bastards broke off the other screw mount when they bashed in the lens.).



started pulling off the heat shields on the exhaust to clean it up. stripped two screws and got frustrated =[ new impact set and left hand bit set were picked up from the hardware store at lunch today, so i'll get back to these tonight.



but thats not all! while trying to get off the back of my left hand switch that also needs to be replaced because the mirror threads are busted i stripped ANOTHER screw.



and lastly, this footpeg is toasted. no way it's getting bent back and can still be safe. plus where the peg is slotted in theres a nice gap in the metal that it could probably end up falling out of if i'm not careful. in any case got one coming from ebay that set me back another $19.



more tonight hopefully...need to mix some 2 stroke so i can rip my DT400 around my little dirt road to keep me sane...
03-07-2018 04:17 PM
Tom Schmitz They were the same as all the Gen 1s, so the ATV or RC high would be a good choice. I don't know what was different about the Gen 2 bars, except the color.
This thread has more than 10 replies. Click here to review the whole thread.

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

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