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

: 1987 to 2007 Wrenching & Mods


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  1. Starter switch
  2. An interesting problem
  3. Swing arm pivot bolt advice
  4. Front Axle Collar
  5. Ignition issues?
  6. Valve Adjustments: A study on how to turn a 1hr job into a 7hr project
  7. Help
  8. Rear suspension
  9. 2002 KLR650 15,000 miles, Electrical problem starting
  10. Advice for Bike Rust
  11. Need your help for heavy engine rebuild
  12. compatibility over many years
  13. Bike won't hold coolant after clutch replacement
  14. Top Gun Chainmaster
  15. Tengai has lost spark.
  16. Im trying to find a part.
  17. The Doo is NOT "Cake" Ya'll; NEW NOISE after reassembly!!!
  18. Never Ending Fix It Quest - Part "Sputtering"
  19. Steering swap - Bearings too?
  20. Options for correcting the speedo
  21. 2004 KLR 650 metal flakes in the oil filter 7700 miles (picture included)
  22. Mechanical noob
  23. 2004 Kawasaki KLR 650 no start and all so confused
  24. 2002 KLR that sat for a decade.
  25. Which rear tire to buy?
  26. For all the Gen 1 fans.
  27. Trying to find the First owner
  28. 2002 KLR metal flakes in Oil
  29. Help removing lowering kit!
  30. Engine mounting bolts
  31. Bought my first KLR, what next?
  32. Installed KLX needle- hesitation
  33. clutch problem
  34. Fork spring guides
  35. Rear shock dimensions
  36. Fuel valve
  37. I lowered using ebay links
  38. Missing something
  39. Changes to 2006 model from prior yr models.
  40. Rotor holder tool. 32mm offset/special wrench or other hub type.
  41. starting help?
  42. Any older KLR gas tanks rusted out-leaking ?
  43. What yr (or) yrs models had the CDI run without or low battery ?
  44. How long(yrs or miles) do KLR coolant hoses last?
  45. Base Service Manual
  46. What is this part?
  47. Bringing down the seat height ( a little ?)
  48. GEN 1 KLR Throttle Tube
  49. 2005 stock Carb
  50. Hidy hole?
  51. Engine stopped, no spark
  52. 99 KLR Engine Behavior
  53. Weirdest Engine Sound
  54. Saving license plate damage
  55. Light bar
  56. 2002 KLR 650 Parts Bike teardown
  57. Tires
  58. Street only tires
  59. 87' Klr650. Wiring loom?
  60. 1987 klr650A1 owners manual?
  61. Discussing CDI charateristics
  62. I've really done it now/ Ignition problem
  63. Carb tuning/air screw
  64. Gen 1 FORK BOOTS
  65. !HELP! Welding Help Needed In Los Angeles Area
  66. KLR 650 Airbox Drain Positions
  67. Water pump issue I need help with
  68. Finally - An Aftermarket Solution For Tank Shrouds
  69. Valve adjustment question
  70. Lights
  71. Rear suspension lever bearing replacement
  72. Mirrors
  73. Choke and plastics
  74. Carberator changes?
  75. Radiator block off
  76. First time buying bike tires
  77. gas tank rubber puck thing
  78. New to me 03
  79. Burning ground when starting
  80. Anyone know if a 2nd gen skid plate will fit a 1st gen?
  81. Benefits of a ported and polished head on a klr with light modifications?
  82. Never Ending Fix It Quest - Part Rear Suspension
  83. Led signal problems!!!!!
  84. Best way to remove paint from the plastic....
  85. 2005 Oil burner mystery
  86. Starter troubles
  87. Primary Drive Seal Install (Counter-Sprocket)
  88. 1st mod- pegs
  89. 140/80-17 Mitas E07 on KLR ?
  90. Garmin Amps mount with power cable connect
  91. Rebuilt - can not get into second
  92. Instrument cluster addition
  93. My tail light mod
  94. Fuel leak at start-up
  95. Thermo Bob.. alternative
  96. Start/running issue
  97. Cracked a piston skirt
  98. Gen 2 rack on Gen 1
  99. Air/Fuel Mixture on newly rebuilt OEM Carb...
  100. Persistent Valve Noise
  101. Gen 1 Clymer Manual Torques/Specs/Schematic (Gen2 as well)
  102. Tube Leak Issue
  103. found this while changing that!
  104. Torques 'n Specs for Gen. 2
  105. Extra Parts... AS ALWAYS!
  106. Changed my Doohickey thingy. Much cussing
  107. Would you trust this CDI?
  108. Yikes
  109. NEW Plastics?
  110. Rear Brake Locking?
  111. Worn Chain
  112. Gen 1 windshield riser?
  113. Quick Timing Question
  114. Rear Shock
  115. ['89 Rebuild] Last piece of the puzzle...high idle after warmed up
  116. Hanging idle
  117. Hesitation in throttle
  118. Digging into new-to-us 2004 KLR w/ ~55k on it - metal shavings and "grabbing" in first gear
  119. The Journey to Vermont
  120. No idle issue
  121. Bike died and now wont start
  122. Oil drain plug stripped
  123. KLR is FKed what pieces did I find in my engine?
  124. Relay Question... Easy but hard???
  125. Fairing stay mounting angle, normal?
  126. No Start
  127. Bike sat for 7 years, bit of smoke
  128. Mystery Part Identification
  129. WT_?!?! Did this CHEAPO DPO chintz out on New Rear Brake Pads OR WHAT?!?!
  130. Que es esto? What's this and will it 'fit' my '03 (larger 'n OEM Rotor)???
  131. Rims, Rims, Rims... DANG RIMS!!! I want Black Ones pleeeeease...
  132. Lemme get this skrait about the Blinker Fluid???
  133. Light 'em up!!!
  134. RattleCanning my Rims and it peeled RIGHT OFF!!!
  135. Weird Carb Slide
  136. Electrical issue: battery dies (Assistance Needed!)
  137. Easy Petcock Conversion
  138. LED Turn Signal Resistor Q
  139. Just clicks
  140. Quick question on clutch hub nut removal
  141. fan doesnt come on?? 06' model
  142. Water pump issue
  143. Mysterious low RPM """Lean""" surging (Yes I already tried KLX needle and adjusted air mix screw) PLEASE HELP!!
  144. Valve noise after oil change
  145. No start thread
  146. M1030b1 parts, also lurking
  147. Safety Switches-Starter Question
  148. Stock Electrical System
  149. 97 KLR resurrection thread
  150. Missing gas tank hose!?
  151. Dual-piston caliper on 1st gen is possible!
  152. Look at this filter!!!
  153. Oil Filter tube?
  154. looking for manual choke plunger 2006
  155. sv 650 caliper stock rotor?
  156. ['89 Rebuild] Speedometer not reading?
  157. Choke plunger
  158. Loose bolt.
  159. 2006 project (pics pending)
  160. Picked up KLR650 Project questions
  161. Starting issue.
  162. Broken Cam Cap question
  163. Air box duct
  164. Shinko 705
  165. KLX Needle Info
  166. Run without balancer chain guard?
  167. Fork alignment procedure
  168. Another oh so un won't start thread...
  169. Air box drain tube?
  170. Where does this go?
  171. whirring noise after service/Doohickey adjustment
  172. Dropped a nut
  173. What break pads to buy?
  174. Canary tweety sound
  175. Footpegs
  176. Parts help
  177. Broken brake assembly
  178. odometer issue
  179. Pre-'96 re-bore options
  180. Help. Found fuel and metal when draining oil
  181. Brake Caliper Rebuild
  182. Tusk Gaskets, garbage?
  183. Thermo bob mod for 2007 KLR
  184. Side Panel Interchangeability?
  185. faded red plastic refurb
  186. Slight chain ‘werring’ noise after doohickey torsion spring install
  187. "New 1987 650
  188. found this little filter thing in my gas tank :O
  189. Tengai fuel tank fit on 2001 klr 650 c
  190. Street tire
  191. Travel Tools
  192. Mechanical/Electrical Systems
  193. Aussie 2003 KLR daily commuter/occasional adventure bike mods on a budget!
  194. Posting Photos to the KLR Forum - Feb. 2018
  195. Rotor Plug Stuck!
  196. jetting question
  197. Idle mixture
  198. Still not there (A17)
  199. Volumetric Efficiency
  200. Transmission issue? Clutch cable issue?
  201. To Lap or not to Lap ... yup, that's the question
  202. Handle Bar Recommendation
  203. 06 smoking and time for maintenance
  204. Oil Leak below Thermobob; weephole
  205. A17 radiator
  206. Rear master flush?
  207. CDI compatibility
  208. Gen 1 Body Parts? KLR600 (NOT KLR650) Transmission
  209. Brake Upgrade
  210. SW Gen2 bashplate to Gen 1?
  211. Plastic Bash Plate
  212. 1998 KLR 650 Carb problems
  213. Newbie: Oil/gas under alternator cover
  214. No headlight low beam
  215. Doohickey tools to lend or sell?
  216. gen1 oil leak
  217. Cold Weather Starting Problems
  218. Looking for Crash Bars Gen 1
  219. 1997 Front wheel hub
  220. Wiring Loom Rebuild, coolant leak?, and Hi
  221. Just put the Lexx Exhaust on, Question ?
  222. Coolant leak - 2003 klr
  223. 99 klr 650 turns over and dies after a few sec
  224. Headlight Failure
  225. Rear shock replace vs rebuild
  226. Swing arm pivot end play
  227. Supercap battery replacement
  228. Leaving off radiator shrouds?
  229. DPelletier's Mistake #7
  230. Inverted Forks and Other Goodies That Will Work?
  231. Cheap Ebay Header, Anyone Hear of These?
  232. Interchangeable Parts
  233. Can someone post a photo of their OEM petcock from a KLR C model (year 2000) please
  234. Borrow rotor wrench for the doo
  235. Headlight Cowls?
  236. Doohickey Tools for loan in Vancouver, BC area?
  237. Backfire once when clutch is pulled
  238. valve check
  239. Replacement Kickstand
  240. Wiring Loom Pin-Out or Diagram?
  241. Upper Engine Rattle - Sounds like pepple boucing around
  242. Recommended sprockets manufacturers (?)
  243. Stranded - Power Loss 05 KLR
  244. Drive Chain Tensioner Plate
  245. Can't flush any fluid through rear brake line? Help!
  246. starting probs .. ? decompressor anyone?
  247. Unhealthy clutch/engine sounds after upgrade
  248. Stock exhaust rattle - loose pipe inside
  249. 1988 KLR650 coolant tank
  250. Another MacGyver Gen 1 Dash