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

: 1987 to 2007 Wrenching & Mods


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