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post #1 of 41 Old 11-27-2015, 05:28 PM Thread Starter
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KamoKLR

I got the opportunity to see my 2016 Kawasaki KLR650 uncrated and assembled today. Iíd previously purchased a set of TKC80s and took delivery with those installed.











The rear Conti barely fit in there and by the time we got it home noticed some minor rub on the inside of the muffler. Planning to change the exhaust but I hadnít expected it to be so tight.





My son and I will get it out tomorrow and start the running in process.

Let the good times roll!
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post #2 of 41 Old 11-27-2015, 06:05 PM
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Bill10,
I could easily be wrong. But in the 5th photo your drive chain appears to be adjusted TOO Tight.

The bottom run of chain needs to be Almost Able to Touch the rear tip of the black plastic chain slider when lifted UP towards the swing arm.
If it can't get near 1/8th inch away, when you set on the bike the drive chain will probably be 'bow-string tight'!

pdwestman
Modify at "YOUR OWN RISK"!

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

Last edited by pdwestman; 11-27-2015 at 06:10 PM. Reason: corrected a typo
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post #3 of 41 Old 11-27-2015, 06:44 PM
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I wanted to mention as well that you can easily space out the muffler for a little more clearance. Just undo the muffler to subframe mounting bolts and stick a couple of flatwashers in there to move it out enough for tire clearance under full suspension compression. I actually had to space mine out the width of a nut to get my Avon Gripsters to clear my stock muffler... Had to run to the hardware store and get some longer bolts as the stockers weren't quite long enough with the nut wedged in there.

Beauty bike by the way, congrats! I really like the new camo theme.
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post #4 of 41 Old 11-28-2015, 02:35 AM
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Looks totally awesome !!!!!


(We won't discuss front fender design anymore)

Sweet ride indeed.

This is my son, with whom I am well pleased." ----God
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post #5 of 41 Old 11-28-2015, 08:04 AM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Bill10,
I could easily be wrong. But in the 5th photo your drive chain appears to be adjusted TOO Tight.

The bottom run of chain needs to be Almost Able to Touch the rear tip of the black plastic chain slider when lifted UP towards the swing arm.
If it can't get near 1/8th inch away, when you set on the bike the drive chain will probably be 'bow-string tight'!
Thanks for the tip. The service manual calls out 1.4 in -- 1.8 in, and while it sure does look tight it's hanging in at 1.75 in.

I've been over it pretty thoroughly. A few loose bolts and I'm trying to figure out if the clutch cable is routed properly...makes a squeak when the bar is turned. Looks properly placed per service manual; may need zip tie. Not sure yet.
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post #6 of 41 Old 11-28-2015, 08:05 AM Thread Starter
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Quote:
Originally Posted by 650Stew View Post
I wanted to mention as well that you can easily space out the muffler for a little more clearance. Just undo the muffler to subframe mounting bolts and stick a couple of flatwashers in there to move it out enough for tire clearance under full suspension compression. I actually had to space mine out the width of a nut to get my Avon Gripsters to clear my stock muffler... Had to run to the hardware store and get some longer bolts as the stockers weren't quite long enough with the nut wedged in there.

Beauty bike by the way, congrats! I really like the new camo theme.
Thank you! Good tip!
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post #7 of 41 Old 11-28-2015, 11:57 AM
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Bill10,
What do you mean "hanging in at a 1.75 inches"?

Is that more than a 1/4 inch from being able to touch the plastic slider when lifted? If so, I definitely wouldn't go Any Tighter!
I'm just trying to help you get Maximum chain and sprocket mileage.

A friend of mine suggested that the local screen print shop could apply the same or similar Digital Camo treatment to those 'shiney' fenders.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 83,000+ miles & counting
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post #8 of 41 Old 11-28-2015, 12:05 PM
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Hi Bill10,
A loose chain is ok where a chain too tight WILL damage the countershaft bearing and seal, wheel bearings and cause excessive chain and sprocket wear.

Nice bike! Looking forward to hear how it works for you!

JJ

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #9 of 41 Old 11-29-2015, 08:06 AM Thread Starter
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The chain slack is 1.75 inches (spec is 1.40 inches to 1.80 inches). The lower run of the chain can be raised to 0.25 inches of the chain guide on the bottom of the swing arm. That's at least in spec.

Three washers got the muffler off the Continental TKC80 enough to prevent it from rubbing any more.

My son and I took the new KLR and the Versys out for a 200 mile loop yesterday. We looped Green Swamp, which has some dreadful road conditions. However, we kept to the paved surfaces.



Some early observations:

Thereís a minor but distinct wobble in the front at speeds north of 65. It might be the Contiís. I took delivery of this bike with the Contiís. But I test rode a 2015 before I bought this one and it didnít have any of that. Thereís a fairly simple steering play inspection procedure in the Service Manual that Iíll check on later.

Gearing might be a little too tall in the lower gears. It seemed that I had to drop it down to 2nd for the most minor maneuvering. Iím not sure thatís going to be very effective when it sees sandy conditions, which is about every condition once off pavement.

Shifting seems very heavy. That is, hard to shift both up and down. Could be that Iím too used to the V. Maybe changing the mineral oil out for synthetic will help a little? The shift lever seems short, too.

The temperature gauge seemed wonky, although upon further research it may be okay. Essentially, when riding the motorcycle, the pin would drop to just above the C-line. Then when stopped and idling, it would work up to mid-range between C and H.

The Service Manual says that mid range on the gauge is 100c/212F, but didnít offer any info on the temps otherwise along the range. Then I found a temp reading overlay offered by watt-man that provides an indication of temps along the range of the gauge (see below). So, running in ambient temps of 65-70, at speeds of 50-65, Iím going to estimate that I was running at a temp as low as 165. That seems low, but the manual also says that the thermostat is set to open at 157-163. Anyway, then when I stopped and idled the pin slowly rose to 210-220. Overall, although I thought it looked weird on the road yesterday, Iím inclined to think allís well here in KLRville unless I hear otherwise from you.



Honestly, the suspension didn't seem all that bad for what it is. Dirt Bike Mag, in a link in this forum, said that Kawa has equipped the 2016 with stiffer springs. Suspension takes a long time to figure out and get acclimated to and dialed in. For now, I'll just say it's better than I thought I was going to get.

Similarly, the seat is supposed to have been improved in 2016. I thought the seat was perfectly fine for the four hours we were out on it yesterday. However, seats are another thing that take some time to figure out, but similar to the suspension, I'd say it's better that what I thought I was going to get.

So far, so good!

__
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post #10 of 41 Old 11-29-2015, 09:47 AM
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Good initial review. The wobble "north of 65" could be the tire assembly needs balancing. I always balance mine and find they nearly always need weight and are smoother afterward. As to the shifting, let it break in for a while before making changes. Everything is new and tight in there. Many guys do go with a longer shifter for better foot placement especially in boots. There are several available but they are all about an inch longer than stock. Let the farkling begin!!
Have fun!
JJ

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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