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

: 1987 to 2007 Wrenching & Mods


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