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Oil drain plug torque?
Certainly not beyond the Generation 1 specification of 17 ft-lb. Even then, given the accuracy and precision of torque wrenches within KLRistas' budgets, I'd suggest . . . "finger tight," plus maybe 1/4 turn, with washer installed.

WHY should this torque be handled gingerly?

BECAUSE, over-tightening of the steel plug can strip the threads of the soft aluminum case halves.

THEN, you will have to endure my, "sermon," on using oversize oil drain plugs in this instance! :)
 

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Tom Schmitz, thank you very much for theses, would it be ok if I loaded the pdf Files to the klr650 wrenchers group on facebook?

If not, i understand completely.
Cheers and thank you

Arctic
 

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Sure. Make sure that credit goes, not to me, but to the originators. All I did was put it into a .pdf and update it a bit for the Gen 2.
 

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Way long time ago, the primary watering hole for the KLR intelligentsia was DSN_KLR650 group as "the discussion group" on yahoo.com. This was before the forums, before platforms such as vBulletin and phpBB had proved to be far better as an richer and more capable interface for the things that consumers were coming to expect in this space. I shamelessly consumed procedures and how-to info and began keeping a personal archive. Doing a lot of solo riding across the southwest, you need to be well versed in road-side repairs ... " and the art of KLR maintenance."

I finally cobble much of this together into a single page pdf. and that was okay. Later (~2003) I found the beautiful handiwork -correct color electrical schematic- of Jim Hyman. In contacting Jim, he very graciously agreed to accept a token payment allowing for the restricted use of his copyrighted work. By agreement the foremost caveat was that his works retain his copyright, and that these are not to be sold or commercially exploited in any fashion. So this was nothing more than the opportunity to put together a handy kwikspec for DIY KLR riders - pay it forward as they say.

So now it's basically a two page, or double sided object, and the original images are best printed double-sided on 8x17 using a color laser printer. These do have tiny tic marks at the 1/3rd positions, which makes them easy to folds for a simple tri-fold, easy to tuck in the tank-bag or pocket.


Mark Bakarich
(aka foo, Old_Six_Fitty, dumbazz650)
 

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Hi Mark, and a hearty welcome to the forum!

Countless riders of clapped-out KLRs owe you a huge debt of gratitude for being the original author.
 
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foo, Thank you also.

That is a long time between visits. April 2007 - August 2019. But I have read many postings from "Old_Six_Fitty" over on the .net site. :)

Ride On.
 
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Mark, oh Mark!

Are you the Mark who posted this info on your website?

Mark's KLR650 Website - Brake Pads Replacement

If so, you may have SAVED MY LIFE todaY! (At least, you insured my Generation 1 KLR 650 will pass state safety inspection!)

My brake pads were non-compliant (as in, GONE); I went to the trusty Internet for "how-to" perform the task, but . . . the entries (including video clips) addressed Generation 2 bikes--much of the information was N/A (not applicable) to my faithful Generation 1 steed.

After being essentially stumped in attempting DIY initially, I came across the link posted above. I printed the procedure out (19 pages), relishing the lucid instructions in the text, and the detailed color diagrams and pictures. For me, victory, at least Virginia DMV safety certification, made possible by your generously-shared know-how and experience. I wondered, HOW MANY others have been rescued from dark despair by your enlightening dissemination of KLR lore, do's and don't's? Their number is legion, surely.

Thanks for your purposeful utilization of the media available through the years, the best aspect of the platforms available.

Understand your website has moved to: http://www.klr650.marknet.us/ (Unsure of the operational status of the website at the moment; hope it's running, or at least, "Coming soon!"

Again, thank you for your contribution to my safe and legal riding, a result of your sharing KLR650 maintenance information. Appreciate the access to KLR650 info now, and into the future.

Welcome to this website!
 

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One of the best features about the KLR was all those who willingly invested their time, talents and often a few bucks to give back their hard won knowledge to the riding community. Makes owning and riding a KLR an infinitely better experience.

Turns out marknet is another yet KLR nerd named Mark. The only thing I contributed to his excellent site was the short how-tos for the Waterpump and the Acerbis front rotor protector. Since he already had a hosted KLR site, I asked him to put those up. In similar fashion, he only get props from other KLR riders rather than revenue.

And Tom, I do have the up-sized banjo bolts sitting on the shelf waiting to be installed during the next valve check routine. Thanks very much to the work that Paul and yourself contributed on pioneering that path!
 

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That's all Paul. He thinks, creates and develops and I scribble.

"If I have seen further it is by standing on the shoulders of Giants." ~ Isaac Newton
 

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And Tom, I do have the up-sized banjo bolts sitting on the shelf waiting to be installed during the next valve check routine. Thanks very much to the work that Paul and yourself contributed on pioneering that path!
That's all Paul. He thinks, creates and develops and I scribble.

"If I have seen further it is by standing on the shoulders of Giants." ~ Isaac Newton
And I can not take the credit for the larger banjo bolts. Kawasaki themselves did that for the 1993 KLX250's & 650's.
They just never upgraded the KLR's with their KLX improvements.

I will take a bow for the oil control orifice, be it installed in to the filter cap or the clutch cover and the 100% filtration mod. :)
 
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