my kl600 thread - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

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post #1 of 14 Old 06-29-2013, 09:12 AM Thread Starter
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my kl600 thread

Hello!

I've started a few threads to get help diagnosing problems and finding solutions as I always think it helps to have a thread on it so that other people with similar problems can find the information nice and easy.

Now I think i've got most of the overall problems diagnosed and chosen my solutions so it's time to execute them! this is my thread to document that process. I'm not an expert, in fact i'm pretty new to wrenching on bikes, so if you too are pretty new perhaps best I say that so if I make mistakes you at least have a good chance of not repeating them after reading this thread!

This forums been really helpful to me and so many generous people on here who know way way way way way more than me (can't even put enough ways) so please you guys get stuck in and tell me if i'm doing something dumb and help me when I don't know what to do! please!

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post #2 of 14 Old 06-29-2013, 09:23 AM Thread Starter
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also, just to say i need to work out what year my bike was manufactured in as at the moment it's on a Q plate which makes it expensive to insure and less valuable to sell. I'm gonna be spending a fair bit (to me anyway) on this bike so it would be nice if I could work out the year put some evidence together and apply for a propper number plate. So if anyone has any tips I can look out for to work out the year that would be awesome.

right, a pic of the bike last year when it took me to italy, a link to a vid of the trip and then on to the wrenching!
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post #3 of 14 Old 06-29-2013, 09:27 AM Thread Starter
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link to vid: .youtube.com/embed/xWcJAYyXgGc

(i can't embed links so you need to do the rest urself if you wanna see it!)

http://youtu.be/xWcJAYyXgGc

pic of the bike at the start of the trip:
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Last edited by Tom Schmitz; 06-30-2013 at 06:19 PM. Reason: Made a clickable link. Cool video...
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post #4 of 14 Old 06-29-2013, 09:35 AM Thread Starter
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so finally the wrenching :

jobs to be done:

doohickey

chain and final drive

rear brakes

electrics ( got everything sorted except indicators)

possibly top end rebuild

front and rear suspension check and tune up(hopefully just a tune up! don't fancy the feel of the rear tho!)

I've stripped the bike down and the first job I'm gonna do is the doohickey (although I have also taken the head cover off and measured the valve clearances)
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post #5 of 14 Old 06-29-2013, 09:47 AM Thread Starter
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interesting

so first interesting thing is this:

and this:

one washer just hanging around doing a bit of gouging in the generator

and one washer sheared in half around the inside of the starter gear

where did that washer in the generator come from??! any suggestions?
and having said it's been gouging around, it actually seems unlikely as if that flimsy little washer had caused those gouges it'd be destroyed but it's actually in pretty good nick. maybe it fell of something when i was taking the cover off and fell in there, but again it seems unlikely as the stator is enclosed by that big old magnet thing so it would have had to get around that

anyways, any suggestions as to where to start investigations, much appreciated!!
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post #6 of 14 Old 06-29-2013, 10:18 AM Thread Starter
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well mystery solved, the two washers are from the starter gears after all, and i'm even missing a third! so we'll se if that turns up!
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post #7 of 14 Old 06-29-2013, 10:57 AM
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I just had one of those in the 650 version in my shop last week, very similar to the larger tank version we get here all the time. I like the stylings of yours better but not the limited range in miles. From what I could see with what I was doing to the bike amny parts interchange between the two versions. I was asked about converting this to the larger tank and body styling, tank I can understand but the rest of it well to each their own.
Keep at it and take your time it's a very simple bike to work on and deal with.
If you get stuck PM me...glad to help.

Willys
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post #8 of 14 Old 06-29-2013, 11:15 AM
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I sure bet the oil screen is full of stuff just looking at the amount of gasket sealer the PO used..Thin washer goes on starter gear one in alt goes on last...Have seen 1and2 thin washers before...I put oil on them so they stay in place when putting cover on....Take your time ,alot of pictures,and good luck.The pictures will really help you and others.Some things easier to show than explain.....Good luck
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post #9 of 14 Old 06-29-2013, 04:10 PM Thread Starter
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Quote:
Originally Posted by willys View Post
I just had one of those in the 650 version in my shop last week, very similar to the larger tank version we get here all the time. I like the stylings of yours better but not the limited range in miles. From what I could see with what I was doing to the bike amny parts interchange between the two versions. I was asked about converting this to the larger tank and body styling, tank I can understand but the rest of it well to each their own.
Keep at it and take your time it's a very simple bike to work on and deal with.
If you get stuck PM me...glad to help.
it's a good looking bike i reckon, glad someone else agrees! sorta grows on ya. could do with the extra miles in the tank tho, ive been caught out by this bike and its dodgy reserve line a couple of times, I'm a put that on the to do list actually. would a tank from the 650 just switch straight on do you think?
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post #10 of 14 Old 06-29-2013, 04:12 PM Thread Starter
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Quote:
Originally Posted by kwoody101 View Post
I sure bet the oil screen is full of stuff just looking at the amount of gasket sealer the PO used..Thin washer goes on starter gear one in alt goes on last...Have seen 1and2 thin washers before...I put oil on them so they stay in place when putting cover on....Take your time ,alot of pictures,and good luck.The pictures will really help you and others.Some things easier to show than explain.....Good luck
lol, reckon the PO had shares in the stuff
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