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Discussion Starter #1
welp, shit happens.

left the KLR on the street one night, and woke up the next day to find it missing. a post on instagram and craigslist actually somehow helped me track it down and with the assistance of the police we recovered the bike. got the call from a good samaritan saying it was ditched a few miles out from where it got stolen behing a set of stairs leading up to an apartment building. here's how we found it:



we loaded it up and got it back to safe haven. here's the damage off the bat:

snapped front left fork
scraped up and broken stator cover
broken taillight and turn signals
bent shifter
stolen license plate
handlebars bent / broken off mirrors
ignition wiring cut









lock up those bikes people...

ordered the stator cover and forks off ebay today, if anyone has any other parts they'd be willing to part with please reach out.
 

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Sorry to hear it was stolen and recovered with damage, but very glad to hear you got it back.

Will be following the rebuild with interest!
 

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I can't fathom what kind of crash scenario could have broken the casting of the LH axle mount off of the fork leg, without creating a pretzel out of the front wheel. Check to see how much of the fracture line looks old.

Maybe it is a good thing that the thief suffered the road rash and possibly a concussion, instead of you?
 

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About the only part I think I might have around that might help is a tail light lens. The same lens is used '84 to current.

If it would help I'd be happy to send it to you. I'd have to find it first...
 

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Hmm, I have a couple of OEM shifters, too. Gen 2, but it might work. I'd have to check the fit on a 600 transmission.
 

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About the only part I think I might have around that might help is a tail light lens. The same lens is used '84 to current.

If it would help I'd be happy to send it to you. I'd have to find it first...
Actually, I thing the lens fits 1984-2007.
 

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Discussion Starter #7
I can't fathom what kind of crash scenario could have broken the casting of the LH axle mount off of the fork leg, without creating a pretzel out of the front wheel. Check to see how much of the fracture line looks old.

Maybe it is a good thing that the thief suffered the road rash and possibly a concussion, instead of you?
pretty sure whoever took it went for a wheelie joyride around the city and crashed it a couple of times until the battery died, he tied the ignition wires together behind the headlight, but yeah you've got a good point.
 

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Actually, I thing the lens fits 1984-2007.
Had to go check; the fiche shows this fitment:
This Kawasaki 23026-1053 LENS,TAIL LAMP is used on these models and components:

1984 KL600-A1 KL600 TAILLIGHT
1985 KL250-D2 KLR250 TAILLIGHT
1985 KL600-B1 KL600 TAILLIGHT
1986 KL250-D3 KLR250 TAILLIGHT
1986 KL600-B2 KL600 TAILLIGHT
1987 KL250-D4 KLR250 TAILLIGHT(S)
1988 KL250-D5 KLR250 TAILLIGHT(S)
1989 KL250-D6 KLR250 TAILLIGHT(S)
1990 KL250-D7 KLR250 TAIL LAMP
1991 KL250-D8 KLR250 TAIL LAMP
1992 KL250-D9 KLR250 TAIL LAMP
1993 KL250-D10 KLR250 TAILLIGHT(S)
1993 KLX650-C1 KLX650 TAILLIGHT(S)@(&NAMI.JKALXEC1 SA021309)
1994 KL250-D11 KLR250 TAILLIGHT(S)
1994 KLX650-C2 KLX650 TAILLIGHT(S)@(&NAMI.JKALXEC1 SA021309)
1995 KL250-D12 KLR250 TAILLIGHT(S)
1995 KLX650-C3 KLX650 TAILLIGHT(S)@(&NAMI.JKALXEC1 SA021309)
1995 KLX650-C3 KLX650 TAILLIGHT(S)@(JKALXEC1 SA021310&NAMI.)
1996 KL250-D13 KLR250 TAILLIGHT(S)
1996 KLX650-C4 KLX650 TAILLIGHT(S)@(JKALXEC1 SA021310&NAMI.)
1997 KL250-D14 KLR250 TAILLIGHT(S)
1998 KL250-D15 KLR250 TAILLIGHT(S)
1999 KL250-D16 KLR250 TAILLIGHT(S)
2000 KL250-D17 KLR250 TAILLIGHT(S)
2001 KL250-D18 KLR250 TAILLIGHT(S)
2002 KL250-D19 KLR250 TAILLIGHT(S)
2003 KL250-D20 KLR250 TAILLIGHT(S)
2004 KL250-D21 KLR250 TAILLIGHT(S)
2005 KL250-D22 KLR250 TAILLIGHT(S)
2006 KLX250H6F KLX250S TAILLIGHT(S)(H6F)
2007 KLX250H7F KLX250S TAILLIGHT(S)(H7F)
2008 KL650E8F KLR650 TAILLIGHT(S)
2009 KL650E9F KLR650 TAILLIGHT(S)
2010 KL650EAF KLR650 TAILLIGHT(S)
2011 KL650EBF KLR650 TAILLIGHT(S)
2012 KL650ECF KLR650 TAILLIGHT(S)
2013 KL650EDF KLR650 TAILLIGHT(S)
2014 KL650EEF KLR650 TAILLIGHT(S)
2014 KL650EES KLR650 New Edition TAILLIGHT(S)
2015 KL650EFF KL650 TAILLIGHT(S)

Not that the fiche (or I) is always right...

Let me know if I'm missing something, Paul. can you see the part number on your '87?
 

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thanks Tom, really appreciate it. Let me know when you've got time.
I'll get to it ASAP. My daughter's car is in the Shop of Horrors for another week or so, so I have to jockey cars to get to the transmission stuff. The lens should be in the Shed of Horrors, but about halfway back in a container behind the lawnmower and all the junque I never use and should throw away.
 

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Discussion Starter #11
I'll get to it ASAP. My daughter's car is in the Shop of Horrors for another week or so, so I have to jockey cars to get to the transmission stuff. The lens should be in the Shed of Horrors, but about halfway back in a container behind the lawnmower and all the junque I never use and should throw away.
awesome. again i really appreciate it, whenever you get there is fine, i'll be focusing on getting the thing standing up again and running. do you have venus flytraps spread out amongst the cars as well?

 

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Well, it wasn't in the Shed of Horrors. Off to move cars and see if it is up in the rafters of the Shop of Horrors.

There are no Venus Flytraps, but there be monsters. As to the Shop of Horrors, it's named for what comes out of it after I'm done working...
 

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23026-1053 lens is correct for the tail light lens for 1986 KL600-B2. My error.

Who would have thought that they would have used that antique part # on their New & Improved model for 2008?
Well I guess it was still in current/continuous use, KLR/KLX 250's.
 

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Damn, my memory sucks.

I found a Gen 2 shifter lever but could not find the rear fender with the lens on it.

Sorry about that!

If you are interested in the shifter lever, PM your address and I'll get it in the mail. I checked and it does fit on the KLR600 splines.
 

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Discussion Starter #15
okay so took a few hours this past weekend to really get into it with the bike. i'd say it was a decently successful day.



new forks! snagged them for a chill 75 shipped from california out to new york. no leaks, honestly cleaner than the old ones. shoutout to the nice guy on ebay who hooked it up, if you're on here, they're going to good use!



further inspection of the broken fork. what a mess. time to dismantle...







lookin' pretty destroyed.





new forks mounted! they seem to be in good working order...

bled down the front caliper so I could at least get it remounted. didn't take photos but it's mounted back on the fork and while i need to re-up on hydraulic fluid, it works.



big thanks to tom for the lever, was a bitch to get the old one off but this one fit on there nicely!

that's all for the happy part of the work...please hold for the depression session...
 

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Discussion Starter #16
so now it's time to look at the damaged stator cover.





but fear not! i snagged a replacement off ebay for 40 shipped.



it's off the bike so might as well hit it with some fresh paint. did the radiator grills as well since they've been rusty since i bought the bike.



and BOOM! disaster hits. turns out there's a small dent in the cover which knocks the threads for the CDI out of alignment. looks like this will take a little bit more than just taking the parts out and reinstalling them in the new case...opinions on if i bend the CDI cross bars/screw holes to fit the threads better, or am i asking for trouble?





also checked out the ignition. thankfully they snipped the ignition cable right before the plug, and other than the two leads tied together for the hot wire, all the cables are there and intact. should be a simple splice together of six wires and we'll see where we stand. get that done, along with the stator cover and then charge up the battery and see if we're back in business.
 

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Well, that's a revoltin' development!

The good news is that a fix isn't limited to finding a KLR600 stator cover. Then there is the bush league approach vs the "as low as $46 fix", vs the "wierd science for $65" fix.

Bush League: The cover is somewhat ductile, as evidenced by the dent. It didn't just break when it was hit. It might be possible, with a hydraulic press and the right punch, to coax it back into the right position. It might show some surface cracking that could be filled with some JB and dressed up. And, it might just break but nothing ventured, nothing gained. All things considered, I wouldn't bend up the crank sensor; the air gap is critical for good signal. You could try it, but if you later have some ignition issues, perhaps a miss at certain RPMs, it would likely be an alignment or air gap issue. Nothing ventured, nothing gained.

As low as $46: The KLR uses the same gasket for that cover from '85 through at least 2015 and probably right up to the current model year. That means that any cover should bolt up. There might be internal differences, though, in the later cases. However, that case was used up through '96, so you're not limited to finding a KLR600 case ('85-'86). There is one with some ugly on it on e-bay; see the first link above. Some patience might find a cheaper/better one in the future.

Weird Science for $65: If you are bold and exploratory, you could try a later case, such as the 2004 shown at the second link above. Again, there might be internal differences, it wouldn't preserve originality, and you'd be breaking some new ground. All in the name of KLR Weird Science and Interchangeability. And, again, some patience might find a cheaper/better one in the future.

Good luck, and Be Mighty...
 

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Discussion Starter #18
well thank god we got some progress over here.

ended up getting a refund from the good man who sold me the original stator cover that i had purchased that didn't work out. used that money to scoop another cover off ebay.



hit that with some VHT...



opened up the old cover and got to doing a switcheroo.. (before)



after!



check out those gashes in that cover...





and all mounted back up! next to go is to rewire the ignition that was snipped.

 

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Sheesh, what did they do, drag it down the road!?
 
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