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

: 1987 to 2007 Wrenching & Mods


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  1. 89 KLR650 slow temp rise uphill
  2. Handlebars
  3. Street Tires?
  4. Replacement foot pegs?
  5. Maintenance records of a dork in Mexico
  6. Took time to check valves tonight
  7. Seeking Higher Performance from a Gen 1, ?'s
  8. 07 KLR Won't Start (Wits End)
  9. website for parts that ship internationally?
  10. JNS DOT compliant headlight mod
  11. Has anyone tried or seen the new Gen1 Maier replacement plastics?
  12. KLR wont start
  13. Front fork swap! Please Help.
  14. Stuttering and popping through exhaust
  15. Start on 705.
  16. Water pump seals, possible infection.
  17. For those that know,,manual choke.
  18. New-to-me '95 KLR650
  19. Changed rear wheel bearings, forgot to put a piece back in
  20. 93 flywheel 'coupler' cracked ? Is this a common thing?
  21. Talk me down off the cliff
  22. Confirmation on CDI wiring bypasses (trying ro remove variables on a weak spark situation)
  23. Spring clip location
  24. Need some Diag help. Running rich or valve issue? Or ignition?
  25. Switched power rear of bike
  26. Water pump mechanical seal kits not fitting
  27. IKEA heat shield
  28. KLR650 Starting Issues and Blowing Smoke
  29. Turn signal stalk mod
  30. Gen 1 Requires Choke even when warm
  31. Battery crowding!
  32. Vibration Dampening
  33. Will the .22 mod fix my new issue?
  34. Dodged a bullet with the Doohickey!
  35. Quickshifter
  36. Did the Doo. Bike idles, dies with throttle
  37. Head refurbishment & mild porting "how-to"
  38. Removing rear wheel, taking caliper off?
  39. Gen 2 front & rear suspension on a Gen 1
  40. KLX, 22c, or nothing?
  41. question swingarm bolt
  42. Engine bogging down at 3-4000 rpm’s
  43. gen 1/gen 2 clutch cover gasket compatibility
  44. Master Link Trouble
  45. Clutch disappeared and then returned!
  46. Fork Spacer Length
  47. Need just the throttle tube for a Gen 1
  48. Gen 1 Brake Upgrade Path
  49. Clutch cable bushing:Can this be replaced?
  50. Welded on bike, may have fried electrics. What to do?
  51. Aftermarket rear rack?
  52. Progressive 465 Rear Spring questions
  53. Thermobob
  54. Engine stops running on hot days
  55. Stuck on this
  56. Gen2 Exhaust on Gen1
  57. IMS Tank with HT Radiator guard?
  58. Eagle Mike Fork Brace
  59. Clutch arm pivot hole elongated
  60. Do you re-torque head gaskets?
  61. Lexx Exhaust Trail Saver Insert.
  62. Gen 1 Gearbox output shaft interchangeability
  63. Bottom end rebuild
  64. Oil Line.......
  65. Doohickey Tools on Vancouver Island
  66. Rotor removal tools and clutch holding tool- available to borrow in UK?
  67. Rear shock leaking 1992 KLR
  68. 1992 Restoration in Italy
  69. Won't run to will run
  70. Not starting
  71. Eagle mike piston kit installation
  72. Nasty clutch noise - failing bearing?
  73. gen 2 kill switch on gen 1 ???
  74. Fuel tank
  75. Starter switch
  76. An interesting problem
  77. Swing arm pivot bolt advice
  78. Front Axle Collar
  79. Ignition issues?
  80. Valve Adjustments: A study on how to turn a 1hr job into a 7hr project
  81. Help
  82. Rear suspension
  83. 2002 KLR650 15,000 miles, Electrical problem starting
  84. Advice for Bike Rust
  85. Need your help for heavy engine rebuild
  86. compatibility over many years
  87. Bike won't hold coolant after clutch replacement
  88. Top Gun Chainmaster
  89. Tengai has lost spark.
  90. Im trying to find a part.
  91. The Doo is NOT "Cake" Ya'll; NEW NOISE after reassembly!!!
  92. Never Ending Fix It Quest - Part "Sputtering"
  93. Steering swap - Bearings too?
  94. Options for correcting the speedo
  95. 2004 KLR 650 metal flakes in the oil filter 7700 miles (picture included)
  96. Mechanical noob
  97. 2004 Kawasaki KLR 650 no start and all so confused
  98. 2002 KLR that sat for a decade.
  99. Which rear tire to buy?
  100. For all the Gen 1 fans.
  101. Trying to find the First owner
  102. 2002 KLR metal flakes in Oil
  103. Help removing lowering kit!
  104. Engine mounting bolts
  105. Bought my first KLR, what next?
  106. Installed KLX needle- hesitation
  107. clutch problem
  108. Fork spring guides
  109. Rear shock dimensions
  110. Fuel valve
  111. I lowered using ebay links
  112. Missing something
  113. Changes to 2006 model from prior yr models.
  114. Rotor holder tool. 32mm offset/special wrench or other hub type.
  115. starting help?
  116. Any older KLR gas tanks rusted out-leaking ?
  117. What yr (or) yrs models had the CDI run without or low battery ?
  118. How long(yrs or miles) do KLR coolant hoses last?
  119. Base Service Manual
  120. What is this part?
  121. Bringing down the seat height ( a little ?)
  122. GEN 1 KLR Throttle Tube
  123. 2005 stock Carb
  124. Hidy hole?
  125. Engine stopped, no spark
  126. 99 KLR Engine Behavior
  127. Weirdest Engine Sound
  128. Saving license plate damage
  129. Light bar
  130. 2002 KLR 650 Parts Bike teardown
  131. Tires
  132. Street only tires
  133. 87' Klr650. Wiring loom?
  134. 1987 klr650A1 owners manual?
  135. Discussing CDI charateristics
  136. I've really done it now/ Ignition problem
  137. Carb tuning/air screw
  138. Gen 1 FORK BOOTS
  139. !HELP! Welding Help Needed In Los Angeles Area
  140. KLR 650 Airbox Drain Positions
  141. Water pump issue I need help with
  142. Finally - An Aftermarket Solution For Tank Shrouds
  143. Valve adjustment question
  144. Lights
  145. Rear suspension lever bearing replacement
  146. Mirrors
  147. Choke and plastics
  148. Carberator changes?
  149. Radiator block off
  150. First time buying bike tires
  151. gas tank rubber puck thing
  152. New to me 03
  153. Burning ground when starting
  154. Anyone know if a 2nd gen skid plate will fit a 1st gen?
  155. Benefits of a ported and polished head on a klr with light modifications?
  156. Never Ending Fix It Quest - Part Rear Suspension
  157. Led signal problems!!!!!
  158. Best way to remove paint from the plastic....
  159. 2005 Oil burner mystery
  160. Starter troubles
  161. Primary Drive Seal Install (Counter-Sprocket)
  162. 1st mod- pegs
  163. 140/80-17 Mitas E07 on KLR ?
  164. Garmin Amps mount with power cable connect
  165. Rebuilt - can not get into second
  166. Instrument cluster addition
  167. My tail light mod
  168. Fuel leak at start-up
  169. Thermo Bob.. alternative
  170. Start/running issue
  171. Cracked a piston skirt
  172. Gen 2 rack on Gen 1
  173. Air/Fuel Mixture on newly rebuilt OEM Carb...
  174. Persistent Valve Noise
  175. Gen 1 Clymer Manual Torques/Specs/Schematic (Gen2 as well)
  176. Tube Leak Issue
  177. found this while changing that!
  178. Torques 'n Specs for Gen. 2
  179. Extra Parts... AS ALWAYS!
  180. Changed my Doohickey thingy. Much cussing
  181. Would you trust this CDI?
  182. Yikes
  183. NEW Plastics?
  184. Rear Brake Locking?
  185. Worn Chain
  186. Gen 1 windshield riser?
  187. Quick Timing Question
  188. Rear Shock
  189. ['89 Rebuild] Last piece of the puzzle...high idle after warmed up
  190. Hanging idle
  191. Hesitation in throttle
  192. Digging into new-to-us 2004 KLR w/ ~55k on it - metal shavings and "grabbing" in first gear
  193. The Journey to Vermont
  194. No idle issue
  195. Bike died and now wont start
  196. Oil drain plug stripped
  197. KLR is FKed what pieces did I find in my engine?
  198. Relay Question... Easy but hard???
  199. Fairing stay mounting angle, normal?
  200. No Start
  201. Bike sat for 7 years, bit of smoke
  202. Mystery Part Identification
  203. WT_?!?! Did this CHEAPO DPO chintz out on New Rear Brake Pads OR WHAT?!?!
  204. Que es esto? What's this and will it 'fit' my '03 (larger 'n OEM Rotor)???
  205. Rims, Rims, Rims... DANG RIMS!!! I want Black Ones pleeeeease...
  206. Lemme get this skrait about the Blinker Fluid???
  207. Light 'em up!!!
  208. RattleCanning my Rims and it peeled RIGHT OFF!!!
  209. Weird Carb Slide
  210. Electrical issue: battery dies (Assistance Needed!)
  211. Easy Petcock Conversion
  212. LED Turn Signal Resistor Q
  213. Just clicks
  214. Quick question on clutch hub nut removal
  215. fan doesnt come on?? 06' model
  216. Water pump issue
  217. Mysterious low RPM """Lean""" surging (Yes I already tried KLX needle and adjusted air mix screw) PLEASE HELP!!
  218. Valve noise after oil change
  219. No start thread
  220. M1030b1 parts, also lurking
  221. Safety Switches-Starter Question
  222. Stock Electrical System
  223. 97 KLR resurrection thread
  224. Missing gas tank hose!?
  225. Dual-piston caliper on 1st gen is possible!
  226. Look at this filter!!!
  227. Oil Filter tube?
  228. looking for manual choke plunger 2006
  229. sv 650 caliper stock rotor?
  230. ['89 Rebuild] Speedometer not reading?
  231. Choke plunger
  232. Loose bolt.
  233. 2006 project (pics pending)
  234. Picked up KLR650 Project questions
  235. Starting issue.
  236. Broken Cam Cap question
  237. Air box duct
  238. Shinko 705
  239. KLX Needle Info
  240. Run without balancer chain guard?
  241. Fork alignment procedure
  242. Another oh so un won't start thread...
  243. Air box drain tube?
  244. Where does this go?
  245. whirring noise after service/Doohickey adjustment
  246. Dropped a nut
  247. What break pads to buy?
  248. Canary tweety sound
  249. Footpegs
  250. Parts help