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Discussion Starter #1
I just picked up a '03 KLR650 that has been sitting in my uncle's garage for about 9 years. He bought it from the original owner with 30,000 miles on it in '05 and it had a noise in the bottom end. He partially disassembled it to find out what the noise was and never put it back together. I don't remember what my uncle told me that the noise was but it wasn't the dohickey but that will be changed while it is apart.

I don't have any immediate plans for it besides getting it back in running order. Joining a forum:stickpoke: is the first step (I am on a lot of forums):13: in finding out what I need to do to get it going.

It came with lots of new parts, gaskets, and plastics. From what I understand from the last email with my Uncle is that it just needed to be reassembled and have a dohickey thrown on for good measure. My uncle died before I could get anymore information about the bike. I will rebuild it in his memories.:(

I have owned several bikes in the past. My first was a 80's Honda XR125 and from there I moved up to a Suzuki DR250. Somewhere in the middle I also had a Trail 90 and a moped of sorts. I sold the DR250 when I graduated high school and haven't had a bike since. I have been aching for soooo long to get back on a bike and out on some trails, maybe even camping.:character00201:
 

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Hello and welcome to the forums! :)

I think that will be a great project for you, and you'll have an excellent bike when it's all reassembled and back in top notch shape. Bonus of it being a KLR is that if any parts are missing, or you need to source replacements, they are easy to find. Nice that your carrying the bike on from your uncle, sounds like he was a cool Uncle to me!

Looking forward to seeing some pics of your project when you get a chance. This forum has a 15 post rule to thwart spam bots. Just means you have to crank out 15 posts before the forum will let you post links or pics. It's a pain in the keester but since it was implemented by the forum owners the spam has dropped almost to nothing. If you want to fast track your post number you can throw test posts up in this thread to get up to 15 quick.
http://www.klrforum.com/showthread.php?t=12677

If you need any help with reassembly don't hesitate to ask, great guys here with tons of KLR knowledge. Enjoy! :bike:
 

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Thanks for the warm welcome. I read about the 15 post min and am looking for posts that I can contribute to without just "spamming" up a thread. I am not much of a poster but a reader so hopefully it won't take too long before I can throw some pictures out there of what I've got and the progress.
 

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Discussion Starter #4
That link to the test section was refreshing.

Commencing photos in 3...2...1...

The day I picked it up:


In my garage. I did nothing but take the seat off (which wasn't bolted on!):


Large bag of plastics for it some black others OD green. The bike has a super trap exhaust but I'm not sure which one go on it so I took them both from my uncles garage.


Large box of parts, new gaskets, timing chain, fuel filter, Clymer manual as well as owners manual, lots of other misc stuff:
 

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Discussion Starter #6
Also, I forgot to mention that my uncle also owned a 2nd gen KLR 650 which he told me that he regretted getting rid of.
 

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Yup! Looks like you got some "puttin togetherin" to do ;). Awesome project though and the KLR's are one of the simplest bikes to work on. :thumb:

On a side note, I love your truck and roof top tent unit! It looks extremely capable!
 

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Plus, if you loaded that old girl with that 2X6 thats under it, you truly are a KLRista! :mexican wave:
 

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On a side note, I love your truck and roof top tent unit! It looks extremely capable!
Thanks! I had to back it up to an uphill driveway so that it was at less of an angle to get the bike up the ramp!

Plus, if you loaded that old girl with that 2X6 thats under it, you truly are a KLRista! :mexican wave:
I did! I did!

Thanks everyone for the warm welcome!

I was just out car shopping with the wife and I mentioned that if we want to sell our car outright rather than trading it in we would have about 4k more for the down payment. What that translates to is that we need the bike running sooner than later so that if we have more than a day or two before we buy the new car I'll have something to get around on. Let's get this party started!
 

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First thing I would get if you don't already have one would be a repair manual. Invaluable tool for working on your bike. Then you can take stock and make sure that you have everything you need, and if you don't you can track down replacements. Luckily KLR parts are plentiful and for the most part reasonably priced... Well, except for heads and cams, they're super expensive cause people keep running them out of oil and buggering them up!.

Looking forward to your progress, you'll have a great rig when your done! :Happy:
 

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Discussion Starter #12
I've got a Clymer manual that came with the bike. I have been making a list of things to do that it recommends. Since the bike has been sitting for 9 years there is a lot of things on that list. I'll start a new post in a appropriate section soon with a lot of questions. I know that it'll be redundant and most likely covered somewhere on this forum. For now I have been doing a lot of reading on the forum and in the book. The next step is inventory, as you mentioned.

... Well, except for heads and cams, they're super expensive cause people keep running them out of oil and buggering them up!.
Is there a common reason for this? Does the oil level need to be checked more often than not?
 

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Some KLR's like to sip some oil when running in the higher RPM ranges on the highway. Usually around 5000 rpm and over. Seems most prevalent in the 2nd generation bikes but I've heard of the 1st gens doing it as well. It's a good practice to at least check your oil at every fill, and keep it at the top of the sight glass. So few vehicles these days use any oil that people forget to keep an eye on it and when it drops too low the top end is starved for oil and it pretty much destroys the head and cams. Big $$$ to replace! But oils cheap so if you keep an eye on it you never have to worry about toasting the top end.
 

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Stew's got'cher back. He's good at this stuff.

The cam and head issues aren't common, but common enough to mention.
It seems to be a unit by unit problem. Some run perfect for years right off the showroom
floor while others may have an oil galley clog up or improperly drilled and a bearing
or lobe here and there runs dry and cooks itself.

As you already know the service manual is an absolute must, plus it pays for itself
the first time or two you use it.

My 2nd generation doesn't have the common oil burning issue but fried the harness
into a melted wad of plastic spaghetti. Hadda make 2/3 of a new wire bundle and it
hasn't been a problem since.

I feel yer uncle's pain. I so much love my '09 that it's the last bike I'll own. Literally.
A little more streetable with the extra plastic and I'm not a motocrosser, but more
of the dirt road adventure type so it fits me excactly!! This is also after an XL and
a DR so I knew what I wanted. Been thru the HD phase in life, rockets, a Gold Wing,
and keep coming back to the dual sport thumpers. This time I got the best.

Have fun!!!!!!!!!!!!

Cheeeeeeeeeeeeeeeeeeeeeeeap
 
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