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

: 1987 to 2007 Wrenching & Mods


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  1. Throttle cable adjustment.
  2. Bike died while riding, fixed it, then it happened again.
  3. Mysterious Coolant Leak....
  4. Fork seal leaking again!!
  5. Air filter mod?
  6. Factory Chain
  7. Output shaft splines stripped
  8. No Spark!! help!! pretty please.
  9. 2004 KLR650 Mixture Screw
  10. 685 Kit Question
  11. Fuel Hose Diameter
  12. I know it's on here somewhere about Valve Adjustment on Gen.1
  13. no idle
  14. New brake disc, front.
  15. Getting Started
  16. All the help
  17. Fork Swap/Upgrade ideas?!
  18. 2005 KLR Highway problems
  19. 89 KLR650 slow temp rise uphill
  20. Handlebars
  21. Street Tires?
  22. Replacement foot pegs?
  23. Maintenance records of a dork in Mexico
  24. Took time to check valves tonight
  25. Seeking Higher Performance from a Gen 1, ?'s
  26. 07 KLR Won't Start (Wits End)
  27. website for parts that ship internationally?
  28. JNS DOT compliant headlight mod
  29. Has anyone tried or seen the new Gen1 Maier replacement plastics?
  30. KLR wont start
  31. Front fork swap! Please Help.
  32. Stuttering and popping through exhaust
  33. Start on 705.
  34. Water pump seals, possible infection.
  35. For those that know,,manual choke.
  36. New-to-me '95 KLR650
  37. Changed rear wheel bearings, forgot to put a piece back in
  38. 93 flywheel 'coupler' cracked ? Is this a common thing?
  39. Talk me down off the cliff
  40. Confirmation on CDI wiring bypasses (trying ro remove variables on a weak spark situation)
  41. Spring clip location
  42. Need some Diag help. Running rich or valve issue? Or ignition?
  43. Switched power rear of bike
  44. Water pump mechanical seal kits not fitting
  45. IKEA heat shield
  46. KLR650 Starting Issues and Blowing Smoke
  47. Turn signal stalk mod
  48. Gen 1 Requires Choke even when warm
  49. Battery crowding!
  50. Vibration Dampening
  51. Will the .22 mod fix my new issue?
  52. Dodged a bullet with the Doohickey!
  53. Quickshifter
  54. Did the Doo. Bike idles, dies with throttle
  55. Head refurbishment & mild porting "how-to"
  56. Removing rear wheel, taking caliper off?
  57. Gen 2 front & rear suspension on a Gen 1
  58. KLX, 22c, or nothing?
  59. question swingarm bolt
  60. Engine bogging down at 3-4000 rpm’s
  61. gen 1/gen 2 clutch cover gasket compatibility
  62. Master Link Trouble
  63. Clutch disappeared and then returned!
  64. Fork Spacer Length
  65. Need just the throttle tube for a Gen 1
  66. Gen 1 Brake Upgrade Path
  67. Clutch cable bushing:Can this be replaced?
  68. Welded on bike, may have fried electrics. What to do?
  69. Aftermarket rear rack?
  70. Progressive 465 Rear Spring questions
  71. Thermobob
  72. Engine stops running on hot days
  73. Stuck on this
  74. Gen2 Exhaust on Gen1
  75. IMS Tank with HT Radiator guard?
  76. Eagle Mike Fork Brace
  77. Clutch arm pivot hole elongated
  78. Do you re-torque head gaskets?
  79. Lexx Exhaust Trail Saver Insert.
  80. Gen 1 Gearbox output shaft interchangeability
  81. Bottom end rebuild
  82. Oil Line.......
  83. Doohickey Tools on Vancouver Island
  84. Rotor removal tools and clutch holding tool- available to borrow in UK?
  85. Rear shock leaking 1992 KLR
  86. 1992 Restoration in Italy
  87. Won't run to will run
  88. Not starting
  89. Eagle mike piston kit installation
  90. Nasty clutch noise - failing bearing?
  91. gen 2 kill switch on gen 1 ???
  92. Fuel tank
  93. Starter switch
  94. An interesting problem
  95. Swing arm pivot bolt advice
  96. Front Axle Collar
  97. Ignition issues?
  98. Valve Adjustments: A study on how to turn a 1hr job into a 7hr project
  99. Help
  100. Rear suspension
  101. 2002 KLR650 15,000 miles, Electrical problem starting
  102. Advice for Bike Rust
  103. Need your help for heavy engine rebuild
  104. compatibility over many years
  105. Bike won't hold coolant after clutch replacement
  106. Top Gun Chainmaster
  107. Tengai has lost spark.
  108. Im trying to find a part.
  109. The Doo is NOT "Cake" Ya'll; NEW NOISE after reassembly!!!
  110. Never Ending Fix It Quest - Part "Sputtering"
  111. Steering swap - Bearings too?
  112. Options for correcting the speedo
  113. 2004 KLR 650 metal flakes in the oil filter 7700 miles (picture included)
  114. Mechanical noob
  115. 2004 Kawasaki KLR 650 no start and all so confused
  116. 2002 KLR that sat for a decade.
  117. Which rear tire to buy?
  118. For all the Gen 1 fans.
  119. Trying to find the First owner
  120. 2002 KLR metal flakes in Oil
  121. Help removing lowering kit!
  122. Engine mounting bolts
  123. Bought my first KLR, what next?
  124. Installed KLX needle- hesitation
  125. clutch problem
  126. Fork spring guides
  127. Rear shock dimensions
  128. Fuel valve
  129. I lowered using ebay links
  130. Missing something
  131. Changes to 2006 model from prior yr models.
  132. Rotor holder tool. 32mm offset/special wrench or other hub type.
  133. starting help?
  134. Any older KLR gas tanks rusted out-leaking ?
  135. What yr (or) yrs models had the CDI run without or low battery ?
  136. How long(yrs or miles) do KLR coolant hoses last?
  137. Base Service Manual
  138. What is this part?
  139. Bringing down the seat height ( a little ?)
  140. GEN 1 KLR Throttle Tube
  141. 2005 stock Carb
  142. Hidy hole?
  143. Engine stopped, no spark
  144. 99 KLR Engine Behavior
  145. Weirdest Engine Sound
  146. Saving license plate damage
  147. Light bar
  148. 2002 KLR 650 Parts Bike teardown
  149. Tires
  150. Street only tires
  151. 87' Klr650. Wiring loom?
  152. 1987 klr650A1 owners manual?
  153. Discussing CDI charateristics
  154. I've really done it now/ Ignition problem
  155. Carb tuning/air screw
  156. Gen 1 FORK BOOTS
  157. !HELP! Welding Help Needed In Los Angeles Area
  158. KLR 650 Airbox Drain Positions
  159. Water pump issue I need help with
  160. Finally - An Aftermarket Solution For Tank Shrouds
  161. Valve adjustment question
  162. Lights
  163. Rear suspension lever bearing replacement
  164. Mirrors
  165. Choke and plastics
  166. Carberator changes?
  167. Radiator block off
  168. First time buying bike tires
  169. gas tank rubber puck thing
  170. New to me 03
  171. Burning ground when starting
  172. Anyone know if a 2nd gen skid plate will fit a 1st gen?
  173. Benefits of a ported and polished head on a klr with light modifications?
  174. Never Ending Fix It Quest - Part Rear Suspension
  175. Led signal problems!!!!!
  176. Best way to remove paint from the plastic....
  177. 2005 Oil burner mystery
  178. Starter troubles
  179. Primary Drive Seal Install (Counter-Sprocket)
  180. 1st mod- pegs
  181. 140/80-17 Mitas E07 on KLR ?
  182. Garmin Amps mount with power cable connect
  183. Rebuilt - can not get into second
  184. Instrument cluster addition
  185. My tail light mod
  186. Fuel leak at start-up
  187. Thermo Bob.. alternative
  188. Start/running issue
  189. Cracked a piston skirt
  190. Gen 2 rack on Gen 1
  191. Air/Fuel Mixture on newly rebuilt OEM Carb...
  192. Persistent Valve Noise
  193. Gen 1 Clymer Manual Torques/Specs/Schematic (Gen2 as well)
  194. Tube Leak Issue
  195. found this while changing that!
  196. Torques 'n Specs for Gen. 2
  197. Extra Parts... AS ALWAYS!
  198. Changed my Doohickey thingy. Much cussing
  199. Would you trust this CDI?
  200. Yikes
  201. NEW Plastics?
  202. Rear Brake Locking?
  203. Worn Chain
  204. Gen 1 windshield riser?
  205. Quick Timing Question
  206. Rear Shock
  207. ['89 Rebuild] Last piece of the puzzle...high idle after warmed up
  208. Hanging idle
  209. Hesitation in throttle
  210. Digging into new-to-us 2004 KLR w/ ~55k on it - metal shavings and "grabbing" in first gear
  211. The Journey to Vermont
  212. No idle issue
  213. Bike died and now wont start
  214. Oil drain plug stripped
  215. KLR is FKed what pieces did I find in my engine?
  216. Relay Question... Easy but hard???
  217. Fairing stay mounting angle, normal?
  218. No Start
  219. Bike sat for 7 years, bit of smoke
  220. Mystery Part Identification
  221. WT_?!?! Did this CHEAPO DPO chintz out on New Rear Brake Pads OR WHAT?!?!
  222. Que es esto? What's this and will it 'fit' my '03 (larger 'n OEM Rotor)???
  223. Rims, Rims, Rims... DANG RIMS!!! I want Black Ones pleeeeease...
  224. Lemme get this skrait about the Blinker Fluid???
  225. Light 'em up!!!
  226. RattleCanning my Rims and it peeled RIGHT OFF!!!
  227. Weird Carb Slide
  228. Electrical issue: battery dies (Assistance Needed!)
  229. Easy Petcock Conversion
  230. LED Turn Signal Resistor Q
  231. Just clicks
  232. Quick question on clutch hub nut removal
  233. fan doesnt come on?? 06' model
  234. Water pump issue
  235. Mysterious low RPM """Lean""" surging (Yes I already tried KLX needle and adjusted air mix screw) PLEASE HELP!!
  236. Valve noise after oil change
  237. No start thread
  238. M1030b1 parts, also lurking
  239. Safety Switches-Starter Question
  240. Stock Electrical System
  241. 97 KLR resurrection thread
  242. Missing gas tank hose!?
  243. Dual-piston caliper on 1st gen is possible!
  244. Look at this filter!!!
  245. Oil Filter tube?
  246. looking for manual choke plunger 2006
  247. sv 650 caliper stock rotor?
  248. ['89 Rebuild] Speedometer not reading?
  249. Choke plunger
  250. Loose bolt.