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

: 1987 to 2007 Wrenching & Mods


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