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

: 1987 to 2007 Wrenching & Mods


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  1. Progressive 465 Rear Spring questions
  2. Thermobob
  3. Engine stops running on hot days
  4. Stuck on this
  5. Gen2 Exhaust on Gen1
  6. IMS Tank with HT Radiator guard?
  7. Eagle Mike Fork Brace
  8. Clutch arm pivot hole elongated
  9. Do you re-torque head gaskets?
  10. Lexx Exhaust Trail Saver Insert.
  11. Gen 1 Gearbox output shaft interchangeability
  12. Bottom end rebuild
  13. Oil Line.......
  14. Doohickey Tools on Vancouver Island
  15. Rotor removal tools and clutch holding tool- available to borrow in UK?
  16. Rear shock leaking 1992 KLR
  17. 1992 Restoration in Italy
  18. Won't run to will run
  19. Not starting
  20. Eagle mike piston kit installation
  21. Nasty clutch noise - failing bearing?
  22. gen 2 kill switch on gen 1 ???
  23. Fuel tank
  24. Starter switch
  25. An interesting problem
  26. Swing arm pivot bolt advice
  27. Front Axle Collar
  28. Ignition issues?
  29. Valve Adjustments: A study on how to turn a 1hr job into a 7hr project
  30. Help
  31. Rear suspension
  32. 2002 KLR650 15,000 miles, Electrical problem starting
  33. Advice for Bike Rust
  34. Need your help for heavy engine rebuild
  35. compatibility over many years
  36. Bike won't hold coolant after clutch replacement
  37. Top Gun Chainmaster
  38. Tengai has lost spark.
  39. Im trying to find a part.
  40. The Doo is NOT "Cake" Ya'll; NEW NOISE after reassembly!!!
  41. Never Ending Fix It Quest - Part "Sputtering"
  42. Steering swap - Bearings too?
  43. Options for correcting the speedo
  44. 2004 KLR 650 metal flakes in the oil filter 7700 miles (picture included)
  45. Mechanical noob
  46. 2004 Kawasaki KLR 650 no start and all so confused
  47. 2002 KLR that sat for a decade.
  48. Which rear tire to buy?
  49. For all the Gen 1 fans.
  50. Trying to find the First owner
  51. 2002 KLR metal flakes in Oil
  52. Help removing lowering kit!
  53. Engine mounting bolts
  54. Bought my first KLR, what next?
  55. Installed KLX needle- hesitation
  56. clutch problem
  57. Fork spring guides
  58. Rear shock dimensions
  59. Fuel valve
  60. I lowered using ebay links
  61. Missing something
  62. Changes to 2006 model from prior yr models.
  63. Rotor holder tool. 32mm offset/special wrench or other hub type.
  64. starting help?
  65. Any older KLR gas tanks rusted out-leaking ?
  66. What yr (or) yrs models had the CDI run without or low battery ?
  67. How long(yrs or miles) do KLR coolant hoses last?
  68. Base Service Manual
  69. What is this part?
  70. Bringing down the seat height ( a little ?)
  71. GEN 1 KLR Throttle Tube
  72. 2005 stock Carb
  73. Hidy hole?
  74. Engine stopped, no spark
  75. 99 KLR Engine Behavior
  76. Weirdest Engine Sound
  77. Saving license plate damage
  78. Light bar
  79. 2002 KLR 650 Parts Bike teardown
  80. Tires
  81. Street only tires
  82. 87' Klr650. Wiring loom?
  83. 1987 klr650A1 owners manual?
  84. Discussing CDI charateristics
  85. I've really done it now/ Ignition problem
  86. Carb tuning/air screw
  87. Gen 1 FORK BOOTS
  88. !HELP! Welding Help Needed In Los Angeles Area
  89. KLR 650 Airbox Drain Positions
  90. Water pump issue I need help with
  91. Finally - An Aftermarket Solution For Tank Shrouds
  92. Valve adjustment question
  93. Lights
  94. Rear suspension lever bearing replacement
  95. Mirrors
  96. Choke and plastics
  97. Carberator changes?
  98. Radiator block off
  99. First time buying bike tires
  100. gas tank rubber puck thing
  101. New to me 03
  102. Burning ground when starting
  103. Anyone know if a 2nd gen skid plate will fit a 1st gen?
  104. Benefits of a ported and polished head on a klr with light modifications?
  105. Never Ending Fix It Quest - Part Rear Suspension
  106. Led signal problems!!!!!
  107. Best way to remove paint from the plastic....
  108. 2005 Oil burner mystery
  109. Starter troubles
  110. Primary Drive Seal Install (Counter-Sprocket)
  111. 1st mod- pegs
  112. 140/80-17 Mitas E07 on KLR ?
  113. Garmin Amps mount with power cable connect
  114. Rebuilt - can not get into second
  115. Instrument cluster addition
  116. My tail light mod
  117. Fuel leak at start-up
  118. Thermo Bob.. alternative
  119. Start/running issue
  120. Cracked a piston skirt
  121. Gen 2 rack on Gen 1
  122. Air/Fuel Mixture on newly rebuilt OEM Carb...
  123. Persistent Valve Noise
  124. Gen 1 Clymer Manual Torques/Specs/Schematic (Gen2 as well)
  125. Tube Leak Issue
  126. found this while changing that!
  127. Torques 'n Specs for Gen. 2
  128. Extra Parts... AS ALWAYS!
  129. Changed my Doohickey thingy. Much cussing
  130. Would you trust this CDI?
  131. Yikes
  132. NEW Plastics?
  133. Rear Brake Locking?
  134. Worn Chain
  135. Gen 1 windshield riser?
  136. Quick Timing Question
  137. Rear Shock
  138. ['89 Rebuild] Last piece of the puzzle...high idle after warmed up
  139. Hanging idle
  140. Hesitation in throttle
  141. Digging into new-to-us 2004 KLR w/ ~55k on it - metal shavings and "grabbing" in first gear
  142. The Journey to Vermont
  143. No idle issue
  144. Bike died and now wont start
  145. Oil drain plug stripped
  146. KLR is FKed what pieces did I find in my engine?
  147. Relay Question... Easy but hard???
  148. Fairing stay mounting angle, normal?
  149. No Start
  150. Bike sat for 7 years, bit of smoke
  151. Mystery Part Identification
  152. WT_?!?! Did this CHEAPO DPO chintz out on New Rear Brake Pads OR WHAT?!?!
  153. Que es esto? What's this and will it 'fit' my '03 (larger 'n OEM Rotor)???
  154. Rims, Rims, Rims... DANG RIMS!!! I want Black Ones pleeeeease...
  155. Lemme get this skrait about the Blinker Fluid???
  156. Light 'em up!!!
  157. RattleCanning my Rims and it peeled RIGHT OFF!!!
  158. Weird Carb Slide
  159. Electrical issue: battery dies (Assistance Needed!)
  160. Easy Petcock Conversion
  161. LED Turn Signal Resistor Q
  162. Just clicks
  163. Quick question on clutch hub nut removal
  164. fan doesnt come on?? 06' model
  165. Water pump issue
  166. Mysterious low RPM """Lean""" surging (Yes I already tried KLX needle and adjusted air mix screw) PLEASE HELP!!
  167. Valve noise after oil change
  168. No start thread
  169. M1030b1 parts, also lurking
  170. Safety Switches-Starter Question
  171. Stock Electrical System
  172. 97 KLR resurrection thread
  173. Missing gas tank hose!?
  174. Dual-piston caliper on 1st gen is possible!
  175. Look at this filter!!!
  176. Oil Filter tube?
  177. looking for manual choke plunger 2006
  178. sv 650 caliper stock rotor?
  179. ['89 Rebuild] Speedometer not reading?
  180. Choke plunger
  181. Loose bolt.
  182. 2006 project (pics pending)
  183. Picked up KLR650 Project questions
  184. Starting issue.
  185. Broken Cam Cap question
  186. Air box duct
  187. Shinko 705
  188. KLX Needle Info
  189. Run without balancer chain guard?
  190. Fork alignment procedure
  191. Another oh so un won't start thread...
  192. Air box drain tube?
  193. Where does this go?
  194. whirring noise after service/Doohickey adjustment
  195. Dropped a nut
  196. What break pads to buy?
  197. Canary tweety sound
  198. Footpegs
  199. Parts help
  200. Broken brake assembly
  201. odometer issue
  202. Pre-'96 re-bore options
  203. Help. Found fuel and metal when draining oil
  204. Brake Caliper Rebuild
  205. Tusk Gaskets, garbage?
  206. Thermo bob mod for 2007 KLR
  207. Side Panel Interchangeability?
  208. faded red plastic refurb
  209. Slight chain ‘werring’ noise after doohickey torsion spring install
  210. "New 1987 650
  211. found this little filter thing in my gas tank :O
  212. Tengai fuel tank fit on 2001 klr 650 c
  213. Street tire
  214. Travel Tools
  215. Mechanical/Electrical Systems
  216. Aussie 2003 KLR daily commuter/occasional adventure bike mods on a budget!
  217. Posting Photos to the KLR Forum - Feb. 2018
  218. Rotor Plug Stuck!
  219. jetting question
  220. Idle mixture
  221. Still not there (A17)
  222. Volumetric Efficiency
  223. Transmission issue? Clutch cable issue?
  224. To Lap or not to Lap ... yup, that's the question
  225. Handle Bar Recommendation
  226. 06 smoking and time for maintenance
  227. Oil Leak below Thermobob; weephole
  228. A17 radiator
  229. Rear master flush?
  230. CDI compatibility
  231. Gen 1 Body Parts? KLR600 (NOT KLR650) Transmission
  232. Brake Upgrade
  233. SW Gen2 bashplate to Gen 1?
  234. Plastic Bash Plate
  235. 1998 KLR 650 Carb problems
  236. Newbie: Oil/gas under alternator cover
  237. No headlight low beam
  238. Doohickey tools to lend or sell?
  239. gen1 oil leak
  240. Cold Weather Starting Problems
  241. Looking for Crash Bars Gen 1
  242. 1997 Front wheel hub
  243. Wiring Loom Rebuild, coolant leak?, and Hi
  244. Just put the Lexx Exhaust on, Question ?
  245. Coolant leak - 2003 klr
  246. 99 klr 650 turns over and dies after a few sec
  247. Headlight Failure
  248. Rear shock replace vs rebuild
  249. Swing arm pivot end play
  250. Supercap battery replacement