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Discussion Starter #1 (Edited)
Hey there,

I'm a long time Honda VFR rider, and I just bought a 94 KLR650 as a project. It's all there, has all the paper work, but has been sitting outside for about a year or so. I have keys, the brakes work, the transmission shifts but I havent been able to turn her over yet (still charging battery). I'm hoping that after some fresh gas, a carb cleaning, and replacing some other fluids, she will fire up for me. I sort of like the idea of having a "rat rod" off roader as long as its safe, but I'm also toying with the idea of a frame up rebuild once I can get some more space.

I read through just about all of the noob sections on the site, and I did learn a few things.

Few questions still linger:

Will most or all parts fit on my 94 if taken from an 87-07 KLR? In other works - besides small style changes in the plastics, are all the hard parts identical?

Where can I download a service/repair manual?

Besides the normal jobs it takes to bring a bike back to life, is there anything in particular I should look out for specific to KLR's? For example, Honda VFR's have notoriously bad Regulator/Rectifiers...

WHO HAS SOME FREE PARTS? haha - Seriously, if anyone has extra nuts + bolts (I'm missing some of the fender bolts, of course and I'm sure many more once I get into it), cables, stock chain + sprockets, stock exhaust pipe + can, and other little nick nacks, I'll gladly throw you a few bucks plus shipping. Think of it like the red paper clip guy, but much cooler!

I'm looking forward to learning a lot from you guys, and adding to the party once I get my new toy all fired up.

Thanks,
Dana

P.S. Who's going down to Laguna MotoGP this July?
 

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Discussion Starter #2
Okay, so good news and bad on the first day (as was expected). The battery is toast, so I hooked up the battery from my VFR. The good news is that the ignition works, as do the lights and controlls for the most part. The horn even gave me a little toot for a split second.

The bad news is that when I hit the starter, all I get a short clicking sound. So I know that power is getting down to the solenoid/starter motor. What's the next step?
 

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The electrical issue sounds like a bad battery.. I don't know if you have boost on your charger, but even that might not be enough.. A new battery will run you around $45 at Wally World, but if you have a spare good battery around, I'd try jumping and seeing if you can get it to run..

Hard parts are pretty much the same for the entire 20 year span..

I haven't seen a downloadable service manual, but I haven't really looked.. I have a Clymer for mine and I just grab it..

The only "issue" is the doohickey.. It's pretty much the weak link on these bikes.. http://klr6500.tripod.com/doohickey.htm

Let us know how the project is going!:)
 

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First off buy a new battery and you'll eliminate a battery problem. I have a cherry 94 klr 650 and I had a problem with the starter. I took out the starter( disconnect battery 1st) and disassembled the starter and there was black soot everywhere. Clean all the soot out with steel wool or fine emery cloth. Especially the copper parts I.E. brush etc. Never had a problem with the starter again. 7 years ago,knock on wood. Change the front brake line to steel braided and you'll see a huge difference. Spongy VS solid brakes. Paulo
 

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