1987 to 2007 Wrenching & Mods [Archive] - Kawasaki KLR 650 Forum

: 1987 to 2007 Wrenching & Mods


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  1. Quickshifter
  2. Did the Doo. Bike idles, dies with throttle
  3. Head refurbishment & mild porting "how-to"
  4. Removing rear wheel, taking caliper off?
  5. Gen 2 front & rear suspension on a Gen 1
  6. KLX, 22c, or nothing?
  7. question swingarm bolt
  8. Engine bogging down at 3-4000 rpm’s
  9. gen 1/gen 2 clutch cover gasket compatibility
  10. Master Link Trouble
  11. Clutch disappeared and then returned!
  12. Fork Spacer Length
  13. Need just the throttle tube for a Gen 1
  14. Gen 1 Brake Upgrade Path
  15. Clutch cable bushing:Can this be replaced?
  16. Welded on bike, may have fried electrics. What to do?
  17. Aftermarket rear rack?
  18. Progressive 465 Rear Spring questions
  19. Thermobob
  20. Engine stops running on hot days
  21. Stuck on this
  22. Gen2 Exhaust on Gen1
  23. IMS Tank with HT Radiator guard?
  24. Eagle Mike Fork Brace
  25. Clutch arm pivot hole elongated
  26. Do you re-torque head gaskets?
  27. Lexx Exhaust Trail Saver Insert.
  28. Gen 1 Gearbox output shaft interchangeability
  29. Bottom end rebuild
  30. Oil Line.......
  31. Doohickey Tools on Vancouver Island
  32. Rotor removal tools and clutch holding tool- available to borrow in UK?
  33. Rear shock leaking 1992 KLR
  34. 1992 Restoration in Italy
  35. Won't run to will run
  36. Not starting
  37. Eagle mike piston kit installation
  38. Nasty clutch noise - failing bearing?
  39. gen 2 kill switch on gen 1 ???
  40. Fuel tank
  41. Starter switch
  42. An interesting problem
  43. Swing arm pivot bolt advice
  44. Front Axle Collar
  45. Ignition issues?
  46. Valve Adjustments: A study on how to turn a 1hr job into a 7hr project
  47. Help
  48. Rear suspension
  49. 2002 KLR650 15,000 miles, Electrical problem starting
  50. Advice for Bike Rust
  51. Need your help for heavy engine rebuild
  52. compatibility over many years
  53. Bike won't hold coolant after clutch replacement
  54. Top Gun Chainmaster
  55. Tengai has lost spark.
  56. Im trying to find a part.
  57. The Doo is NOT "Cake" Ya'll; NEW NOISE after reassembly!!!
  58. Never Ending Fix It Quest - Part "Sputtering"
  59. Steering swap - Bearings too?
  60. Options for correcting the speedo
  61. 2004 KLR 650 metal flakes in the oil filter 7700 miles (picture included)
  62. Mechanical noob
  63. 2004 Kawasaki KLR 650 no start and all so confused
  64. 2002 KLR that sat for a decade.
  65. Which rear tire to buy?
  66. For all the Gen 1 fans.
  67. Trying to find the First owner
  68. 2002 KLR metal flakes in Oil
  69. Help removing lowering kit!
  70. Engine mounting bolts
  71. Bought my first KLR, what next?
  72. Installed KLX needle- hesitation
  73. clutch problem
  74. Fork spring guides
  75. Rear shock dimensions
  76. Fuel valve
  77. I lowered using ebay links
  78. Missing something
  79. Changes to 2006 model from prior yr models.
  80. Rotor holder tool. 32mm offset/special wrench or other hub type.
  81. starting help?
  82. Any older KLR gas tanks rusted out-leaking ?
  83. What yr (or) yrs models had the CDI run without or low battery ?
  84. How long(yrs or miles) do KLR coolant hoses last?
  85. Base Service Manual
  86. What is this part?
  87. Bringing down the seat height ( a little ?)
  88. GEN 1 KLR Throttle Tube
  89. 2005 stock Carb
  90. Hidy hole?
  91. Engine stopped, no spark
  92. 99 KLR Engine Behavior
  93. Weirdest Engine Sound
  94. Saving license plate damage
  95. Light bar
  96. 2002 KLR 650 Parts Bike teardown
  97. Tires
  98. Street only tires
  99. 87' Klr650. Wiring loom?
  100. 1987 klr650A1 owners manual?
  101. Discussing CDI charateristics
  102. I've really done it now/ Ignition problem
  103. Carb tuning/air screw
  104. Gen 1 FORK BOOTS
  105. !HELP! Welding Help Needed In Los Angeles Area
  106. KLR 650 Airbox Drain Positions
  107. Water pump issue I need help with
  108. Finally - An Aftermarket Solution For Tank Shrouds
  109. Valve adjustment question
  110. Lights
  111. Rear suspension lever bearing replacement
  112. Mirrors
  113. Choke and plastics
  114. Carberator changes?
  115. Radiator block off
  116. First time buying bike tires
  117. gas tank rubber puck thing
  118. New to me 03
  119. Burning ground when starting
  120. Anyone know if a 2nd gen skid plate will fit a 1st gen?
  121. Benefits of a ported and polished head on a klr with light modifications?
  122. Never Ending Fix It Quest - Part Rear Suspension
  123. Led signal problems!!!!!
  124. Best way to remove paint from the plastic....
  125. 2005 Oil burner mystery
  126. Starter troubles
  127. Primary Drive Seal Install (Counter-Sprocket)
  128. 1st mod- pegs
  129. 140/80-17 Mitas E07 on KLR ?
  130. Garmin Amps mount with power cable connect
  131. Rebuilt - can not get into second
  132. Instrument cluster addition
  133. My tail light mod
  134. Fuel leak at start-up
  135. Thermo Bob.. alternative
  136. Start/running issue
  137. Cracked a piston skirt
  138. Gen 2 rack on Gen 1
  139. Air/Fuel Mixture on newly rebuilt OEM Carb...
  140. Persistent Valve Noise
  141. Gen 1 Clymer Manual Torques/Specs/Schematic (Gen2 as well)
  142. Tube Leak Issue
  143. found this while changing that!
  144. Torques 'n Specs for Gen. 2
  145. Extra Parts... AS ALWAYS!
  146. Changed my Doohickey thingy. Much cussing
  147. Would you trust this CDI?
  148. Yikes
  149. NEW Plastics?
  150. Rear Brake Locking?
  151. Worn Chain
  152. Gen 1 windshield riser?
  153. Quick Timing Question
  154. Rear Shock
  155. ['89 Rebuild] Last piece of the puzzle...high idle after warmed up
  156. Hanging idle
  157. Hesitation in throttle
  158. Digging into new-to-us 2004 KLR w/ ~55k on it - metal shavings and "grabbing" in first gear
  159. The Journey to Vermont
  160. No idle issue
  161. Bike died and now wont start
  162. Oil drain plug stripped
  163. KLR is FKed what pieces did I find in my engine?
  164. Relay Question... Easy but hard???
  165. Fairing stay mounting angle, normal?
  166. No Start
  167. Bike sat for 7 years, bit of smoke
  168. Mystery Part Identification
  169. WT_?!?! Did this CHEAPO DPO chintz out on New Rear Brake Pads OR WHAT?!?!
  170. Que es esto? What's this and will it 'fit' my '03 (larger 'n OEM Rotor)???
  171. Rims, Rims, Rims... DANG RIMS!!! I want Black Ones pleeeeease...
  172. Lemme get this skrait about the Blinker Fluid???
  173. Light 'em up!!!
  174. RattleCanning my Rims and it peeled RIGHT OFF!!!
  175. Weird Carb Slide
  176. Electrical issue: battery dies (Assistance Needed!)
  177. Easy Petcock Conversion
  178. LED Turn Signal Resistor Q
  179. Just clicks
  180. Quick question on clutch hub nut removal
  181. fan doesnt come on?? 06' model
  182. Water pump issue
  183. Mysterious low RPM """Lean""" surging (Yes I already tried KLX needle and adjusted air mix screw) PLEASE HELP!!
  184. Valve noise after oil change
  185. No start thread
  186. M1030b1 parts, also lurking
  187. Safety Switches-Starter Question
  188. Stock Electrical System
  189. 97 KLR resurrection thread
  190. Missing gas tank hose!?
  191. Dual-piston caliper on 1st gen is possible!
  192. Look at this filter!!!
  193. Oil Filter tube?
  194. looking for manual choke plunger 2006
  195. sv 650 caliper stock rotor?
  196. ['89 Rebuild] Speedometer not reading?
  197. Choke plunger
  198. Loose bolt.
  199. 2006 project (pics pending)
  200. Picked up KLR650 Project questions
  201. Starting issue.
  202. Broken Cam Cap question
  203. Air box duct
  204. Shinko 705
  205. KLX Needle Info
  206. Run without balancer chain guard?
  207. Fork alignment procedure
  208. Another oh so un won't start thread...
  209. Air box drain tube?
  210. Where does this go?
  211. whirring noise after service/Doohickey adjustment
  212. Dropped a nut
  213. What break pads to buy?
  214. Canary tweety sound
  215. Footpegs
  216. Parts help
  217. Broken brake assembly
  218. odometer issue
  219. Pre-'96 re-bore options
  220. Help. Found fuel and metal when draining oil
  221. Brake Caliper Rebuild
  222. Tusk Gaskets, garbage?
  223. Thermo bob mod for 2007 KLR
  224. Side Panel Interchangeability?
  225. faded red plastic refurb
  226. Slight chain ‘werring’ noise after doohickey torsion spring install
  227. "New 1987 650
  228. found this little filter thing in my gas tank :O
  229. Tengai fuel tank fit on 2001 klr 650 c
  230. Street tire
  231. Travel Tools
  232. Mechanical/Electrical Systems
  233. Aussie 2003 KLR daily commuter/occasional adventure bike mods on a budget!
  234. Posting Photos to the KLR Forum - Feb. 2018
  235. Rotor Plug Stuck!
  236. jetting question
  237. Idle mixture
  238. Still not there (A17)
  239. Volumetric Efficiency
  240. Transmission issue? Clutch cable issue?
  241. To Lap or not to Lap ... yup, that's the question
  242. Handle Bar Recommendation
  243. 06 smoking and time for maintenance
  244. Oil Leak below Thermobob; weephole
  245. A17 radiator
  246. Rear master flush?
  247. CDI compatibility
  248. Gen 1 Body Parts? KLR600 (NOT KLR650) Transmission
  249. Brake Upgrade
  250. SW Gen2 bashplate to Gen 1?