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

: 1987 to 2007 Wrenching & Mods


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