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So how much of a performance increase would one see going from 650 to 685 to 691? Or even the 719 kit...from stock...
 

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So how much of a performance increase would one see going from 650 to 685 to 691? Or even the 719 kit...from stock...
From 2 - 4 HP.

Doesn't the 719 kit need a thicker cast iron sleeve to be installed?

If you really want to help the 685 or 692 kits or even stock 651 or EM 661 kits make the power they are capable of then the cylinder head needs to be properly ported.

Proper porting should be the First thing done when in search of more power, not the last thing.

Read here, https://www.klrchris.com/klr650-small-port-head/
 

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a hair more than the jump in displacement would warrant alone; so a 685 is 6% bigger.....stock power is 34hp, so with no other changes, expect a 3 hp boost or so. 719 would be more like 5-6.

Unless you are doing a max effort with porting, valves, cams, etc., I'd stick with the 685 though (as you can see) it isn't worth it from a $$$/hp perspective. The 685 is a popular upgrade to solve typical oil burning problems due to poor ring oil control and to lessen vibration....small output boost is just a bonus IMO. I personally wouldn't tear into a perfectly running KLR engine to do the 685 unless there was a compelling reason to do so.

old but a good read: Patman's Kawasaki KLR650 KLR 650 Dyno Results

Also check out: https://www.klrchris.com/

you can get 2-3hp or so without messing with the engine internals; KLX jet kit, Uni-Filter, snorkle-ectomy, L-mod and a decent silencer..... Big power from a KLR is an exercise in diminshing returns IMO.....now about that suspension! LOL

Cheers,
Dave
 
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