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

: 1987 to 2007 Wrenching & Mods


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  1. Dropped the bike/clutch question...
  2. How to increase power on my first gen KLR 650 ?
  3. Brake upgrades
  4. Can bad true make front slithly crooked?
  5. 2005 Won't Start - Sad New Member...
  6. Gen 1 Carb Mod/ OPPS! WRONG YEAR
  7. Left light switch assembly Gen 2 on Gen 1?
  8. fan not operating
  9. '07 Electrical Short - FIXED
  10. Sprocket Hub Question
  11. Clutch housing big sprung gear
  12. Metal flake in oil
  13. So....... I wrecked:) Bent rim
  14. Speedometer Drive Rebuild - Suggestions Please
  15. Alright what'd I break now
  16. Shifer issue question
  17. Alternator cover torque specs?
  18. 2005 Gen 1 Fuel Tank Venting??
  19. Doohickey
  20. Carburetor Help - Unable to Cold Start After Rebuild
  21. Gen 1 fork bushings- Made of gold?!
  22. Subframe bolt size 2006
  23. Front wheel alignment procedure
  24. Paint/plastic advice
  25. Wind Screen, Wind Sheild, Plastic Protector
  26. Just looking for my fronts options
  27. 3d printed turn signals
  28. New cool tool
  29. Best KLR Tank Bag
  30. fork issues.
  31. Pre 1996 Balancer Weight and Springs
  32. Low mile 99 650 running issues
  33. Speedometer issues
  34. 2005 KLR650 wont start in rain
  35. Front fender lowering
  36. forks
  37. Speedometer sticks, odometer works
  38. Hard to start long cranking
  39. Sub frame bolt size
  40. Rebuild/ 685 kit cost?
  41. White smoke from something burning in exhaust
  42. Squeaky Speedo
  43. Throttle cable adjustment.
  44. Bike died while riding, fixed it, then it happened again.
  45. Mysterious Coolant Leak....
  46. Fork seal leaking again!!
  47. Air filter mod?
  48. Factory Chain
  49. Output shaft splines stripped
  50. No Spark!! help!! pretty please.
  51. 2004 KLR650 Mixture Screw
  52. 685 Kit Question
  53. Fuel Hose Diameter
  54. I know it's on here somewhere about Valve Adjustment on Gen.1
  55. no idle
  56. New brake disc, front.
  57. Getting Started
  58. All the help
  59. Fork Swap/Upgrade ideas?!
  60. 2005 KLR Highway problems
  61. 89 KLR650 slow temp rise uphill
  62. Handlebars
  63. Street Tires?
  64. Replacement foot pegs?
  65. Maintenance records of a dork in Mexico
  66. Took time to check valves tonight
  67. Seeking Higher Performance from a Gen 1, ?'s
  68. 07 KLR Won't Start (Wits End)
  69. website for parts that ship internationally?
  70. JNS DOT compliant headlight mod
  71. Has anyone tried or seen the new Gen1 Maier replacement plastics?
  72. KLR wont start
  73. Front fork swap! Please Help.
  74. Stuttering and popping through exhaust
  75. Start on 705.
  76. Water pump seals, possible infection.
  77. For those that know,,manual choke.
  78. New-to-me '95 KLR650
  79. Changed rear wheel bearings, forgot to put a piece back in
  80. 93 flywheel 'coupler' cracked ? Is this a common thing?
  81. Talk me down off the cliff
  82. Confirmation on CDI wiring bypasses (trying ro remove variables on a weak spark situation)
  83. Spring clip location
  84. Need some Diag help. Running rich or valve issue? Or ignition?
  85. Switched power rear of bike
  86. Water pump mechanical seal kits not fitting
  87. IKEA heat shield
  88. KLR650 Starting Issues and Blowing Smoke
  89. Turn signal stalk mod
  90. Gen 1 Requires Choke even when warm
  91. Battery crowding!
  92. Vibration Dampening
  93. Will the .22 mod fix my new issue?
  94. Dodged a bullet with the Doohickey!
  95. Quickshifter
  96. Did the Doo. Bike idles, dies with throttle
  97. Head refurbishment & mild porting "how-to"
  98. Removing rear wheel, taking caliper off?
  99. Gen 2 front & rear suspension on a Gen 1
  100. KLX, 22c, or nothing?
  101. question swingarm bolt
  102. Engine bogging down at 3-4000 rpm’s
  103. gen 1/gen 2 clutch cover gasket compatibility
  104. Master Link Trouble
  105. Clutch disappeared and then returned!
  106. Fork Spacer Length
  107. Need just the throttle tube for a Gen 1
  108. Gen 1 Brake Upgrade Path
  109. Clutch cable bushing:Can this be replaced?
  110. Welded on bike, may have fried electrics. What to do?
  111. Aftermarket rear rack?
  112. Progressive 465 Rear Spring questions
  113. Thermobob
  114. Engine stops running on hot days
  115. Stuck on this
  116. Gen2 Exhaust on Gen1
  117. IMS Tank with HT Radiator guard?
  118. Eagle Mike Fork Brace
  119. Clutch arm pivot hole elongated
  120. Do you re-torque head gaskets?
  121. Lexx Exhaust Trail Saver Insert.
  122. Gen 1 Gearbox output shaft interchangeability
  123. Bottom end rebuild
  124. Oil Line.......
  125. Doohickey Tools on Vancouver Island
  126. Rotor removal tools and clutch holding tool- available to borrow in UK?
  127. Rear shock leaking 1992 KLR
  128. 1992 Restoration in Italy
  129. Won't run to will run
  130. Not starting
  131. Eagle mike piston kit installation
  132. Nasty clutch noise - failing bearing?
  133. gen 2 kill switch on gen 1 ???
  134. Fuel tank
  135. Starter switch
  136. An interesting problem
  137. Swing arm pivot bolt advice
  138. Front Axle Collar
  139. Ignition issues?
  140. Valve Adjustments: A study on how to turn a 1hr job into a 7hr project
  141. Help
  142. Rear suspension
  143. 2002 KLR650 15,000 miles, Electrical problem starting
  144. Advice for Bike Rust
  145. Need your help for heavy engine rebuild
  146. compatibility over many years
  147. Bike won't hold coolant after clutch replacement
  148. Top Gun Chainmaster
  149. Tengai has lost spark.
  150. Im trying to find a part.
  151. The Doo is NOT "Cake" Ya'll; NEW NOISE after reassembly!!!
  152. Never Ending Fix It Quest - Part "Sputtering"
  153. Steering swap - Bearings too?
  154. Options for correcting the speedo
  155. 2004 KLR 650 metal flakes in the oil filter 7700 miles (picture included)
  156. Mechanical noob
  157. 2004 Kawasaki KLR 650 no start and all so confused
  158. 2002 KLR that sat for a decade.
  159. Which rear tire to buy?
  160. For all the Gen 1 fans.
  161. Trying to find the First owner
  162. 2002 KLR metal flakes in Oil
  163. Help removing lowering kit!
  164. Engine mounting bolts
  165. Bought my first KLR, what next?
  166. Installed KLX needle- hesitation
  167. clutch problem
  168. Fork spring guides
  169. Rear shock dimensions
  170. Fuel valve
  171. I lowered using ebay links
  172. Missing something
  173. Changes to 2006 model from prior yr models.
  174. Rotor holder tool. 32mm offset/special wrench or other hub type.
  175. starting help?
  176. Any older KLR gas tanks rusted out-leaking ?
  177. What yr (or) yrs models had the CDI run without or low battery ?
  178. How long(yrs or miles) do KLR coolant hoses last?
  179. Base Service Manual
  180. What is this part?
  181. Bringing down the seat height ( a little ?)
  182. GEN 1 KLR Throttle Tube
  183. 2005 stock Carb
  184. Hidy hole?
  185. Engine stopped, no spark
  186. 99 KLR Engine Behavior
  187. Weirdest Engine Sound
  188. Saving license plate damage
  189. Light bar
  190. 2002 KLR 650 Parts Bike teardown
  191. Tires
  192. Street only tires
  193. 87' Klr650. Wiring loom?
  194. 1987 klr650A1 owners manual?
  195. Discussing CDI charateristics
  196. I've really done it now/ Ignition problem
  197. Carb tuning/air screw
  198. Gen 1 FORK BOOTS
  199. !HELP! Welding Help Needed In Los Angeles Area
  200. KLR 650 Airbox Drain Positions
  201. Water pump issue I need help with
  202. Finally - An Aftermarket Solution For Tank Shrouds
  203. Valve adjustment question
  204. Lights
  205. Rear suspension lever bearing replacement
  206. Mirrors
  207. Choke and plastics
  208. Carberator changes?
  209. Radiator block off
  210. First time buying bike tires
  211. gas tank rubber puck thing
  212. New to me 03
  213. Burning ground when starting
  214. Anyone know if a 2nd gen skid plate will fit a 1st gen?
  215. Benefits of a ported and polished head on a klr with light modifications?
  216. Never Ending Fix It Quest - Part Rear Suspension
  217. Led signal problems!!!!!
  218. Best way to remove paint from the plastic....
  219. 2005 Oil burner mystery
  220. Starter troubles
  221. Primary Drive Seal Install (Counter-Sprocket)
  222. 1st mod- pegs
  223. 140/80-17 Mitas E07 on KLR ?
  224. Garmin Amps mount with power cable connect
  225. Rebuilt - can not get into second
  226. Instrument cluster addition
  227. My tail light mod
  228. Fuel leak at start-up
  229. Thermo Bob.. alternative
  230. Start/running issue
  231. Cracked a piston skirt
  232. Gen 2 rack on Gen 1
  233. Air/Fuel Mixture on newly rebuilt OEM Carb...
  234. Persistent Valve Noise
  235. Gen 1 Clymer Manual Torques/Specs/Schematic (Gen2 as well)
  236. Tube Leak Issue
  237. found this while changing that!
  238. Torques 'n Specs for Gen. 2
  239. Extra Parts... AS ALWAYS!
  240. Changed my Doohickey thingy. Much cussing
  241. Would you trust this CDI?
  242. Yikes
  243. NEW Plastics?
  244. Rear Brake Locking?
  245. Worn Chain
  246. Gen 1 windshield riser?
  247. Quick Timing Question
  248. Rear Shock
  249. ['89 Rebuild] Last piece of the puzzle...high idle after warmed up
  250. Hanging idle