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

: 1987 to 2007 Wrenching & Mods


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  1. Do you re-torque head gaskets?
  2. Lexx Exhaust Trail Saver Insert.
  3. Gen 1 Gearbox output shaft interchangeability
  4. Bottom end rebuild
  5. Oil Line.......
  6. Doohickey Tools on Vancouver Island
  7. Rotor removal tools and clutch holding tool- available to borrow in UK?
  8. Rear shock leaking 1992 KLR
  9. 1992 Restoration in Italy
  10. Won't run to will run
  11. Not starting
  12. Eagle mike piston kit installation
  13. Nasty clutch noise - failing bearing?
  14. gen 2 kill switch on gen 1 ???
  15. Fuel tank
  16. Starter switch
  17. An interesting problem
  18. Swing arm pivot bolt advice
  19. Front Axle Collar
  20. Ignition issues?
  21. Valve Adjustments: A study on how to turn a 1hr job into a 7hr project
  22. Help
  23. Rear suspension
  24. 2002 KLR650 15,000 miles, Electrical problem starting
  25. Advice for Bike Rust
  26. Need your help for heavy engine rebuild
  27. compatibility over many years
  28. Bike won't hold coolant after clutch replacement
  29. Top Gun Chainmaster
  30. Tengai has lost spark.
  31. Im trying to find a part.
  32. The Doo is NOT "Cake" Ya'll; NEW NOISE after reassembly!!!
  33. Never Ending Fix It Quest - Part "Sputtering"
  34. Steering swap - Bearings too?
  35. Options for correcting the speedo
  36. 2004 KLR 650 metal flakes in the oil filter 7700 miles (picture included)
  37. Mechanical noob
  38. 2004 Kawasaki KLR 650 no start and all so confused
  39. 2002 KLR that sat for a decade.
  40. Which rear tire to buy?
  41. For all the Gen 1 fans.
  42. Trying to find the First owner
  43. 2002 KLR metal flakes in Oil
  44. Help removing lowering kit!
  45. Engine mounting bolts
  46. Bought my first KLR, what next?
  47. Installed KLX needle- hesitation
  48. clutch problem
  49. Fork spring guides
  50. Rear shock dimensions
  51. Fuel valve
  52. I lowered using ebay links
  53. Missing something
  54. Changes to 2006 model from prior yr models.
  55. Rotor holder tool. 32mm offset/special wrench or other hub type.
  56. starting help?
  57. Any older KLR gas tanks rusted out-leaking ?
  58. What yr (or) yrs models had the CDI run without or low battery ?
  59. How long(yrs or miles) do KLR coolant hoses last?
  60. Base Service Manual
  61. What is this part?
  62. Bringing down the seat height ( a little ?)
  63. GEN 1 KLR Throttle Tube
  64. 2005 stock Carb
  65. Hidy hole?
  66. Engine stopped, no spark
  67. 99 KLR Engine Behavior
  68. Weirdest Engine Sound
  69. Saving license plate damage
  70. Light bar
  71. 2002 KLR 650 Parts Bike teardown
  72. Tires
  73. Street only tires
  74. 87' Klr650. Wiring loom?
  75. 1987 klr650A1 owners manual?
  76. Discussing CDI charateristics
  77. I've really done it now/ Ignition problem
  78. Carb tuning/air screw
  79. Gen 1 FORK BOOTS
  80. !HELP! Welding Help Needed In Los Angeles Area
  81. KLR 650 Airbox Drain Positions
  82. Water pump issue I need help with
  83. Finally - An Aftermarket Solution For Tank Shrouds
  84. Valve adjustment question
  85. Lights
  86. Rear suspension lever bearing replacement
  87. Mirrors
  88. Choke and plastics
  89. Carberator changes?
  90. Radiator block off
  91. First time buying bike tires
  92. gas tank rubber puck thing
  93. New to me 03
  94. Burning ground when starting
  95. Anyone know if a 2nd gen skid plate will fit a 1st gen?
  96. Benefits of a ported and polished head on a klr with light modifications?
  97. Never Ending Fix It Quest - Part Rear Suspension
  98. Led signal problems!!!!!
  99. Best way to remove paint from the plastic....
  100. 2005 Oil burner mystery
  101. Starter troubles
  102. Primary Drive Seal Install (Counter-Sprocket)
  103. 1st mod- pegs
  104. 140/80-17 Mitas E07 on KLR ?
  105. Garmin Amps mount with power cable connect
  106. Rebuilt - can not get into second
  107. Instrument cluster addition
  108. My tail light mod
  109. Fuel leak at start-up
  110. Thermo Bob.. alternative
  111. Start/running issue
  112. Cracked a piston skirt
  113. Gen 2 rack on Gen 1
  114. Air/Fuel Mixture on newly rebuilt OEM Carb...
  115. Persistent Valve Noise
  116. Gen 1 Clymer Manual Torques/Specs/Schematic (Gen2 as well)
  117. Tube Leak Issue
  118. found this while changing that!
  119. Torques 'n Specs for Gen. 2
  120. Extra Parts... AS ALWAYS!
  121. Changed my Doohickey thingy. Much cussing
  122. Would you trust this CDI?
  123. Yikes
  124. NEW Plastics?
  125. Rear Brake Locking?
  126. Worn Chain
  127. Gen 1 windshield riser?
  128. Quick Timing Question
  129. Rear Shock
  130. ['89 Rebuild] Last piece of the puzzle...high idle after warmed up
  131. Hanging idle
  132. Hesitation in throttle
  133. Digging into new-to-us 2004 KLR w/ ~55k on it - metal shavings and "grabbing" in first gear
  134. The Journey to Vermont
  135. No idle issue
  136. Bike died and now wont start
  137. Oil drain plug stripped
  138. KLR is FKed what pieces did I find in my engine?
  139. Relay Question... Easy but hard???
  140. Fairing stay mounting angle, normal?
  141. No Start
  142. Bike sat for 7 years, bit of smoke
  143. Mystery Part Identification
  144. WT_?!?! Did this CHEAPO DPO chintz out on New Rear Brake Pads OR WHAT?!?!
  145. Que es esto? What's this and will it 'fit' my '03 (larger 'n OEM Rotor)???
  146. Rims, Rims, Rims... DANG RIMS!!! I want Black Ones pleeeeease...
  147. Lemme get this skrait about the Blinker Fluid???
  148. Light 'em up!!!
  149. RattleCanning my Rims and it peeled RIGHT OFF!!!
  150. Weird Carb Slide
  151. Electrical issue: battery dies (Assistance Needed!)
  152. Easy Petcock Conversion
  153. LED Turn Signal Resistor Q
  154. Just clicks
  155. Quick question on clutch hub nut removal
  156. fan doesnt come on?? 06' model
  157. Water pump issue
  158. Mysterious low RPM """Lean""" surging (Yes I already tried KLX needle and adjusted air mix screw) PLEASE HELP!!
  159. Valve noise after oil change
  160. No start thread
  161. M1030b1 parts, also lurking
  162. Safety Switches-Starter Question
  163. Stock Electrical System
  164. 97 KLR resurrection thread
  165. Missing gas tank hose!?
  166. Dual-piston caliper on 1st gen is possible!
  167. Look at this filter!!!
  168. Oil Filter tube?
  169. looking for manual choke plunger 2006
  170. sv 650 caliper stock rotor?
  171. ['89 Rebuild] Speedometer not reading?
  172. Choke plunger
  173. Loose bolt.
  174. 2006 project (pics pending)
  175. Picked up KLR650 Project questions
  176. Starting issue.
  177. Broken Cam Cap question
  178. Air box duct
  179. Shinko 705
  180. KLX Needle Info
  181. Run without balancer chain guard?
  182. Fork alignment procedure
  183. Another oh so un won't start thread...
  184. Air box drain tube?
  185. Where does this go?
  186. whirring noise after service/Doohickey adjustment
  187. Dropped a nut
  188. What break pads to buy?
  189. Canary tweety sound
  190. Footpegs
  191. Parts help
  192. Broken brake assembly
  193. odometer issue
  194. Pre-'96 re-bore options
  195. Help. Found fuel and metal when draining oil
  196. Brake Caliper Rebuild
  197. Tusk Gaskets, garbage?
  198. Thermo bob mod for 2007 KLR
  199. Side Panel Interchangeability?
  200. faded red plastic refurb
  201. Slight chain ‘werring’ noise after doohickey torsion spring install
  202. "New 1987 650
  203. found this little filter thing in my gas tank :O
  204. Tengai fuel tank fit on 2001 klr 650 c
  205. Street tire
  206. Travel Tools
  207. Mechanical/Electrical Systems
  208. Aussie 2003 KLR daily commuter/occasional adventure bike mods on a budget!
  209. Posting Photos to the KLR Forum - Feb. 2018
  210. Rotor Plug Stuck!
  211. jetting question
  212. Idle mixture
  213. Still not there (A17)
  214. Volumetric Efficiency
  215. Transmission issue? Clutch cable issue?
  216. To Lap or not to Lap ... yup, that's the question
  217. Handle Bar Recommendation
  218. 06 smoking and time for maintenance
  219. Oil Leak below Thermobob; weephole
  220. A17 radiator
  221. Rear master flush?
  222. CDI compatibility
  223. Gen 1 Body Parts? KLR600 (NOT KLR650) Transmission
  224. Brake Upgrade
  225. SW Gen2 bashplate to Gen 1?
  226. Plastic Bash Plate
  227. 1998 KLR 650 Carb problems
  228. Newbie: Oil/gas under alternator cover
  229. No headlight low beam
  230. Doohickey tools to lend or sell?
  231. gen1 oil leak
  232. Cold Weather Starting Problems
  233. Looking for Crash Bars Gen 1
  234. 1997 Front wheel hub
  235. Wiring Loom Rebuild, coolant leak?, and Hi
  236. Just put the Lexx Exhaust on, Question ?
  237. Coolant leak - 2003 klr
  238. 99 klr 650 turns over and dies after a few sec
  239. Headlight Failure
  240. Rear shock replace vs rebuild
  241. Swing arm pivot end play
  242. Supercap battery replacement
  243. Leaving off radiator shrouds?
  244. DPelletier's Mistake #7
  245. Inverted Forks and Other Goodies That Will Work?
  246. Cheap Ebay Header, Anyone Hear of These?
  247. Interchangeable Parts
  248. Can someone post a photo of their OEM petcock from a KLR C model (year 2000) please
  249. Borrow rotor wrench for the doo
  250. Headlight Cowls?