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1. Why does my transmission slip out of gear Several possibilities that involve the shift lever and are thankfully easy to fix Check to see if the shift lever is hitting the skid plate that you presumably just added if it is loose on the shaft or if the base weld is beginning to break on the stock unit Fuel Intake return to top file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 13 of 41 Why does the bike pop on deceleration The bike is jetted very lean from the factory You can enrich the idle mixture by removing the pilot screw cap and backing the screw out 1 2 to 3 4 turn from its factory setting The pilot screw is located on the engine side of the carb in front of the bowl on the bottom It is underneath a plug which must be drilled through to remove Note that it may be illegal to tamper with carb settings in your state Note that this symptom can also indicate an exhaust leak so check all of the exhaust connections first How do I keep the carb diaphragm seated while I replace the cap Put a thin film of grease in the groove this will hold the diaphragm in place If you manage to pinch a hole in it see the next item Is there a cheaper slide diaphragm assembly available Harley dealers carry a slide diaphragm assembly part number 27585 88 for Kehin CVK40 carbs List price is usually around 40 For a temporary repair Park Tool makes small
2. for fitting MX boots under the tip Gas in the right side of the tank Because of the gas tank design even if you run dry on reserve there will still be gas in the right side of the tank To get at this gas in an emergency tilt the bike over to the left as far as possible and start riding again You may be able to repeat this process a few times This can be avoided by installing Skip Faulkner s fuel tank mod Weak subframe mounting The subframe supports the seat and rear rack and is mounted by four 10 9 M8 bolts two socket heads on top two hex heads on bottom Under heavy loading or harsh riding the upper bolts can break pulling off the exhaust wiring harness etc One option is to replace the upper bolts with grade 12 9 bolts The strongest fix is to drill through the upper frame and subframe mounts and install an M10 bolt all the way through Kits for this are available from Eagle Manufacturing and Dual Star Swingarm lubrication The swingarm bearings are installed with only a minimal amount of grease It is best to relube the swingarm at your earliest convenience especially if you will be riding in a lot of water See the maintenance section for more details Rear hub bearing spacer When doing rear wheel maintenance people often lose the middle bearing spacer It generally stays in place due to grease and you may pull the hub off several times without ever noticing it If it happens to fall out though you will soon
3. Should I use hi octane fuel Only if your engine pings under load High octane gasoline does not contain any more energy than low octane and is intended to reduce the possibility of pre ignition and detonation which can be a problem with high compression engines An engine can gain nothing from higher octane gasoline if it is not designed to take advantage of it That being said any change that increases the peak compression pressure 1 e increasing the charge of air can cause pinging requiring higher octane gasoline These changes include opening up the intake path increasing valve size intake cam duration etc However file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 14 of 41 these changes are usually small and can also be cured with jetting Excessive carbon deposits in older engines can also increase the effective compression ratio or provide hot spots for pre ignition requiring higher octane gasoline Can I Install a Fuel Filter Many people have experienced problems with fuel filters There is not enough height of gas in the tank to get sufficient flow in many filters after the tank is less than half full This causes the engine to stall unexpectedly often while on the highway due to the increased fuel flow required while traveling at higher speed Paper type automotive filters are very prone to this problem since they are designed to be installed in an applic
4. 41 e 88 89 uses OEM P N 13144 1103 Not interchangable with other years Retainer holes are 42mm center to center Post 90 is 37 center to center e 90 95 uses OEM P N 13144 1163 Can be used on 90 04 splines are the same e 96 04 uses OEM P N 13144 1253 Not sure if ok for 90 95 diagram shows 6 holes don t know if they are threaded for retainer Most aftermarkets ok for 90 04 Why is oil dripping from the countershaft sprocket cover This can go two ways If you re lucky it s just chain lube that got flung off onto the cover and is dripping out If you re not lucky you got an overtightened chain and the countershaft seal is shot This seal is under pressure so you can lose oil quickly if it goes It s not too hard to replace if you want to do it yourself You can either drive a sheet metal screw into either side of the seal and pull it out or remove the sprocket start the engine and put it in gear The oil pressure will drive out the seal so be ready There is an O ring behind the seal but don t pull it off unless you have a new one When driving on the new seal be aware that the case does NOT have a shoulder Don t overdrive the seal stop when it becomes flush with the case What kind of chain can I use Any quality O ring or X ring chain should be fine for example the DID 520 VM gold The manual states that the chain must be an endless type however most people run a clip type master with no problems The size i
5. Big Gun provides lots of power with rejetting but seems to need repacking most often and is quite loud when the packing disintegrates The Supertrapp comes in two flavors the exposed disc race series and enclosed disc ISDE series These are generally durable and not as bad when the packing disintegrates The Laser is stainless steel requires no packing and gives higher flow without much noise The downsides are the price and weight and at this time it does not have a USFS approved spark arrestor it has reportedly passed but the test but the current batch doesn t have the stamp Be aware of tire interference with any replacement exhaust you might need to use a longer spacer on the mounting bolt Note also that the head pipe from the next generation KLR650 is a bolt on replacement for the old pipe and supposedly has smoother bends than the stock pipe You will also need the new heat shield and fittings the old one won t fit Is there a better packing material Stainless steel wool can be used instead of fiberglass Make sure it s stainless so it won t burn Use the finest grade you can find It isn t as fine and therefore not as quiet as fiberglass but it should last indefinitely How do I repack a Supertrapp In brief If there are any dents in the case it will be tough Remove the midpipe clamp and the rivet that pins the core to the midpipe underneath it DO NOT use a punch and hammer on the inside forward edges of the cor
6. Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 32 of 41 think you re overdue How do I lubricate the swingarm linkage Jack up the bike so it is fully supported and the rear wheel is just touching the ground Remove all of the linkage bolts Note that to remove the main swingarm pivot you must also remove the engine mount bolt above the pivot You will need a big breaker bar liquid wrench and possibly a propane torch to loosen the bolts The bolts may also be stuck in the pivots due to corrosion You may have to tap them out with a hammer and drift pin Pack the bearings with grease and reassemble Before reinstalling the bolts coat them with grease to prevent corrosion You can avoid this mess in the future if you install zerk fittings for a grease gun Watt Man has the procedure on his site What replacement spark plugs can I use Standard spark plug replacements are either the NGK DPR8EA 9 or ND NipponDenso X24EPR U9 For Iridium there is the NGK DPR8EIX 9 You can also use a Champion 809 RA6HC which is available with a 5 8 hex so you can use commonly available spark plug sockets The Autolite 4163 and MP4163 premium are also choices Gap is 0 032 0 036 0 8 0 9 mm torque to 10 ft lbs 14 N m How do I adjust the valves Valves are shim over bucket type meaning you have to use different thickness shims to obtain the desired clearance Proper clearances are 0 10 0 20 mm intake 0 15 0 25 mm exhaust
7. NGK Formtech Trailtech Panoram computers IMS Products Moose Offroad IKAT WestCo Accessories Apparel accessories Ignition boosters Batteries Motion Pro FETE TE eee Eastern Beaver Centech Wire Tools Controls Electrical Fuse Blocks Carbeuretors Spark plug info Urethane guides SKF Bearings Supertrapp oe Mufflers ae Webcamshafts Nashbar Eastwood Company Restoration mat ls Battery Mart Custom Dynamics Topografix Batteries Batt gage LED lamps Mapping software Reflective Decals RAM Mounts Die cut reflective Ti ae GPS electronic decals wrench mounts Cams Bicycle Computers Manufacturers Luggage A pparel Eclipse Joe Rocket Chase Harper Teknic Luggage Apparel Luggage Luggage apparel Mags Bags Rev Pack Wolfman USA RKA Luggage Luggage Luggage Luggage Tourmaster Nelson Rigg First Gear Hein Gericke Luggage apparel Luggage Clothing Clothing Cycleport Helen 2Wheels Gerbing Child Riding Belt Apparel Luggage Heated clothing Security strap OEM Dealers e Arrowhead Motorsports carries OEM parts as well as aftermarket items the owner knows his stuff and is happy to help e Ron Ayers Motorsports and Bike Bandit carry OEM parts and have online fiche and price lookup e You can also look up part numbers at Kawasaki com Other suppliers Reel Rider Southwest Moto Tires Superbright LEDs Film productions Discount tire prices LEDs _ a a file C Documents
8. and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 41 of 41 TPI Motorcycle Parts Batteries Plus Trail Tech General supplies Batteries and Batt Testing Compact HID lights BLM lt Accessories makes accessory mounting shelves Powerlet Products carries a number of auxiliary power plugs carbparts com for you guessed it carbuerator parts Motorcycle Keys the Kawasaki 4L amp 4R are the ones for the KLR Pro Flo steering stem bearings Dave Quinn Motorcycles for Hagon shortened shocks Scootworks makes lowering links for the KLR Johnson Bearings be sure to tell them you want the good stuff Hartco lambskin seat covers Cyclebrakes com brake parts Sunmate Cushions carries seat foam and covers BLM Accessories has skidplates Arizona Tools carries well tools General Accessory Dealers Cycoactive Good company lots of GPS stuff tools mapcases and other small carry bags Rider Warehouse Another favorite makers of Aerostitch clothing also carry a wide variety of adventure touring gear Dennis Kirk Chaparral Racing Rocky Mountain ATV Motorcycle Accessory Warehouse Hi Per Sports Competition Accessories mostly sportbike stuff but they do have clothing and a 10 discount for AMA members Whitehorse Press Lots of motorcycling books and a selection of tools and gear Motorcycle Closeouts has low prices on gear New Enough Leathers has new and used apparrel at good pric
9. and a hammer drive the screwdriver into and along the seam opening it up to within 1 of the end Start the motor and listen for tweety If it s still there make another lengthwise slit at the 12 00 position start the motor and check Some people have had to make four slits at 90 degree intervals to fix the tweet e Send your exhaust to Kientech Engineering for modification they are actually a DR operation but have done KLR exhausts as well Do I really need to clean the spark arrestor on the stock muffler No one has ever gotten any carbon out of the muffler via the cleaning plugs In fact the more likely result is that the plugs will shear off If you re really intent on doing the procedure you will need to remove the drain plugs when the bike is brand new and apply anti seize to them file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 16 of 41 Why is my exhaust running hotter An exhaust leak can lean out your mixture and make the exhaust hotter Check the header nuts for tightness as well as the other clamps Also note that a loose midclamp behind the rear brake reservoir can vent exhaust and melt a hole in your airbox What aftermarket exhausts are available There are several Supertrapp Big Gun and Laser Pro Duro are the most popular others include the Two Brothers The first two are aluminum USFS approved and require repacking at some interval The
10. as well For SKF bearings the suffix 2RS indicates double rubber shields the ones you want and ZZ are metal shielded The bearings are pressed so freezing them will make them easier to install Also remember to remove the retaining rings before taking the old ones out Rear wheel sprocket carrier 6004 Rear wheel sprocket side 6003 Rear wheel disc side 6204 Front wheel left side 6202 Front wheel right side 6203 What tire pressure should I run On the highway it s best to run the tires at full recommended pressure check chart or even higher as long as you don t exceed the rating stamped on the tire 32 32 is a decent level Offroad lower pressures assist in traction float on soft surfaces and also act as a suspension component in smoothing out the ride 18 20 is a good starting point and if you go lower see the section on rim locks you get an even nicer ride At lower pressures consider using heavier tubes to avoid pinch flats which occur when the tire hits a rock and deforms so much that the tube gets pinched between the bead and rim Do I need to replace the cotter pin when I remove an axle Cotter pins should only be used once As an alternative you can use a hairpin cotter also known as an R pin which clips in and out and can be reused Dual Star also carries self locking Fuji Lock reusable flange nuts for both axles If using these however you will need to carry two axle wrenches as you need to wre
11. called Shockwears available from Arrowhead Motor Sports How much preload should I set on the rear The rear suspension should compress about 3 from the combined weight of you and the bike First tilt the bike onto the side stand to top out the rear suspension and have someone measure the distance from the rear axle to some point directly above it Then get on the bike balance it upright and only put one foot lightly on the floor to keep it balanced Have your friend measure the distance again and the difference between the two measurements is the sag Adjust the preload as required to get 3 of sag Note When riding on your typical terrain if you don t bottom the suspension out once and a while you probably have it set too stiff Does the rear shock need any maintenance The preload adjuster gears are small and fairly fragile If you re frequently adjusting your preload you should clean and lubricate the gears Insert the spray tube from a can of WD 40 into the small holes around the top of the shock to flush and lube the gear mechanism What bearings are used for the rear suspension file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 31 of 41 The rear suspension rquires the following Koyo bearings or equivalent e Swingarm 4x BM 2026 needle bearings KHI 92046 1110 6x MHA 20 27 5 7F seals KHI 92049 1109 e Pivot linkage 2x BM 2817 large needle bearings KHI
12. clear flexible patches for bicycle tubes that will do the job Is there a less vulnerable choke lever available With the choke out on the handlebar it s possible to break it when you dump the bike Lister Zach found a short choke cable for the CVK40 from Harley Davidson Part 29229 88C Cable Carburetor Enrichment You need to come up with a mounting bracket but you can check out an installation in the links section While you re down there be careful about breaking the plastic choke fitting on the carb You can get an aluminum one from Stead Engineering Why does my gas tank whistle This is the tank venting system It doesn t happen on all bikes and may relate to how well the vent in the cap seals to the bung in the cap socket Why is my bike running poorly Start with these Clogged pilot jet Crud in float needle valve preventing closure or full flow Torn carb diaphragm usually midrange running problems Plugged carb vent hose do the T mod Plugged gas tank vent preventing creating a vacuum in tank stalling starvation on highway Drain hose is full the ones with the caps reservoirs drain and recap Vacuum line to petcock is collapsing when it gets hot causing fuel starvation Inline fuel filter aftermarket is restricting flow the in tank screens are usually pretty clean Gas boiling in fuel line if it s very hot out generally over 100 105 deg F and if side shroud vents are covered e Valve clearance at limits
13. compressed Propensity to shed fasteners The vibrations from a thumper are capable of unscrewing a number of fasteners As soon as you get the bike home it would be a good idea to get to know your machine by removing fasteners and reinstalling them with blue 242 Loctite Some of the more critical ones are the front fender body panels and muffler bolts but it s easier to say that I ve never seen the engine case or suspension bolts work loose Everything else is fair game Fuel capacity The actual stock fuel capacity is around 5 6 5 7 gallons Older resources did list 5 7 gallons but newer ones claim 6 1 Bike stalls in the rain deep water crossings This is generally caused by submersion of the carbeurator vent line This is a clear transparent pink hose running from the side of the carb down to the bottom of the bike If this gets clogged the carb will fail to operate properly and the engine will quit The best solution is known as the T mod install a tee in this line near the carb Route the original line the way it was and route a second line up under the seat or behind the fairing Arrowhead Motorsports now sells a kit for this Balancer chain tensioner Doohickey prone to failure The counterbalancer tensioner arm clamped down by the small bolt on the bottom left engine cover has a tendency to get brittle and break This has happened on bikes of all years and mileages while many other bikes of all years and mileages are f
14. information on mods maintenance procedures adventuring etc KLRWorld Mark St Hillaire Tamm Watt Man Tom Grennon The Larkins Conall Ericjazz DualSport Groups Tours Kansas AR LA TX Ontario PA Punks Sound WA Backroads Touring ArkLaTex ODSC ReelRider g Southern California PF Left Coast KLRs South Africa KLR Accessory Manufacturers Most of the parts mentioned in the FAQ are made by major manufacturers and are available through your dealer the internet or mail order However there are some custom parts that are sold only by the manufacturers These are listed below e Eagle Manufacturing home of Mike Cowlishaw e Happy Trails Luggage racks highway pegs more e Formtech Services formerly Dirtly Polyurethane chain guides e buykawasaki com for factory luggage and accessories e Dual Star Guards luggage body plastic subframe upgrade more e KLR rider Don Beck Olympia WA offers lowering links at good prices e Mark Schuette makes carriers for mountain bikes and other unwieldy items e Mega Cams 90 Mitchel Blvd San Rafael CA 94903 415 472 3195 used to make cams for the KLR Good Garages I m a little reluctant to put this in here because I haven t personally visited ANY of these shops But they have at one time or another gotten a good word or two from a rider You ll have to make your own call e La Paz Baja California Sur Mexico Honda Dealership at Abasolo and Jalisco phone 0161212
15. or just shoot some hairspray into them and slide them on Many grips also have circumferential slots for tying down with safety wire Are vibration resistant mirrors available Mirrors from the Honda XR650L have vibration dampeners You need to order two each of 88210 KAE 871 mirror 90301 KBA 900 mirror locking nut 88255 KAE 871 rubber mount 90303 428 900 rubber mount nut There are also less expensive substitutes available from Ken Sean folding mirrors and Four Strokes Only links Can I use a different key blank for the ignition If you don t want to shell out the big bucks for a Kawasaki factory key blank here are some alternatives that should work Of the keys listed below the Silca KW14 and KWIAR are the only truly correct ones It would probably be best to take the whole list to your key shop and let them pick the one that will work the best NOTE The KLR comes with both right and left hand keys the direction of the offset in the cross section So not every blank will work SILCA KW14 KW14R Curtis YM 58 Yamaha Ford 5 cut primary blank ILCO KAI5 X106 ILCO YH38 X77 ILCO X120 YH46 Taylor X90 X91 Curtis SU 9 Suzuki Why is there shimmy in my front wheel Steering shimmy can come from a variety of sources Try different tire pressures and check your tire balance Make sure there is no twist in the forks Support the bike on a stand loosen the top and bottom triple clamp bolts don t let the fork drop out wiggle t
16. place foam in them You will need to install a grate on the inside of the door to retain the foam file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 15 of 41 Can I rejet the carb Rejetting is essential if you increase flow in the intake or exhaust Dynojet makes a kit with an adjustable needle and several main jets It also includes a drill bit for removing the pilot screw cover A less expensive alternative is to use a KLX650R needle N1TB 16009 1794 spacer 92143 1667 and clip 92037 1401 which which will give you an adjustable needle You can then buy individual Kehin main jets to adjust the carb A point of note To remove the pilot screw cap you must drill a hole in it Drill very slowly and pull back on the drill as soon as or even before you break through so you don t drive into the screw and damage it You can also use a left hand drill which will prevent you from accidentally driving the screw into its seat How do the Dynojet jets compare to the stock ones Dynojet jet numbers are not the same as Keihin numbers The DJ136 is roughly comparable to the KH148 although may be a bit richer The DJ140 is richer than the KH148 Can I get a different carb If you wish to switch to a slide carb the Mikuni 38mm RS carb will fit as will the Keihin 39mm FCR the 41mm will not fit This will give better throttle response but will make throttle modulation more import
17. this is crank horsepower measured on an engine dyno and doesn t account for losses in the transmission or final drive At the rear wheel power is around 38 hp Devon Jarvis supplied a dyno chart for his bike that shows a peak of 36 hp DynoJet dyno run hot humid day His bike was fully stock except the pilot screw was backed out to 1 25 turns Another extensive comparison of KLR mods can be found at Patman Racing If you re looking for a lot more power you are probably better off with a different bike The KLR does not lend itself well to hop ups and many owners have spent much time and aggravation chasing what amounted to a couple of extra hp and crappy gas mileage You re better off spending the money on suspension upgrades that way you ll be able to maintain speed rather than have to slow down and speed up all of the time Why does my bike lurch stall the first time I put it in gear This problem is common to all wet clutch bikes In a multi plate clutch the clutch release can only remove pressure from the end of the disc stack it can t actually drive all of the discs apart When the bike sits for a while the oil squeezes out from between the clutch plates making them stick together Squeezing the clutch lever takes the spring pressure off of them but they still stick so when you put the bike in gear for the first time after starting it the engine has to break the discs apart This makes the bike lurch or can stall it To prevent
18. wreck the hub Click here for a diagram of the rear hub 42036 is the one you need to watch out for It goes in the inside of the sprocket carrier Pay careful attention to how many threads on the axle are showing above the axle nut before you loosen it When you reinstall the wheel if you see noticeably more threads something s wrong Or if you bottom the nut and the wheel still isn t tight Poor speedometer accuracy The KLR speedo generally reads about 10 higher than true speed This depends on what front tire you are running and how worn it is A re calibration procedure is provided by the Watt Man Engine return to top What type of oil should I use How much oil should I put in How often should I change my oil On any motorcycle list any of these questions will provoke a response greater than that to the assasination of Archduke Ferdinand The answers are basically motor oil enough and when you need to Many use automotive oils particularly Castrol GTX for conventional oil and Mobil 1 for synthetic Others swear by motorcycle specific oils Delvac 1300 and Rotella T are popular oils that are available in bulk quantities One point of note is that if you use a bargain oil it is possible to stain the sight glass making it difficult to see the oil level Also you generally want to avoid 5W oils and some manufacturers l10W 30 oils As long as it doesn t say Energy Conserving II around the rim of the API seal on the
19. 650 FAQ Page 37 of 41 KLR guru Eldon Carl finally has a website Mike Silverstein s KLR tire page Share gps tracks in any format at bike stu ph Importing bikes from Canada Conall Diesel KLR information from the manufacturer Jane s take on the diesel KLR The KLR Adventure list at Yahoo Groups is focused on long distance adventure touring with the KLR Dual Sport News the magazine sponsoring the list This has articles on adventure touring and bikes with occasional highlights on the KLR Their website also has technical and product information The print version has reviews tech info and trip reports Information on the Laser Pro Duro exhaust from Arrowhead Tammy s dualsportrider org Glenn s KLR650 forum The Adventure Touring mailing list has information on long distance touring If you would like more info on the KLX try the KLX 650 Group at Yahoo The DSN DR group has information on the Suzuki DR Info on the XR650L and XR650R The full parts fiche for the KLR can be found at Kawasaki com so you can look up the numbers for parts you need and take them straight to your dealer Look at the Parts Diagrams selection under Owner Info in the menu at left You can also find the parts fiche at Bike Bandit and Ron Ayers Towing services AAA RV AMA MoTow MTS Towing Spark arrestor info Off road com Maintenance Mod Procedures Mark St Hilaire s webpage has a number of illustrated proce
20. 89044 email distribuidor115 hotmail com Father son operation Luke speaks English Repair file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 39 of 41 Engine Dynamics Motorcycle Radiator GPS Suspension Gary Pro Tec Performance Head repairs Radiator repair Reworks stock shocks Shock rebuilds Precision Concepts Shock rebuilds Manufacturers Suspension Progressive Suspension WP Suspension Eshocks Kytech Shocks springs Shocks Shocks springs Fork braces Works Performance Suspension Manufacturers Tires ee EN Tire Balls Angs TES Tire mousse balls Manufacturers Body Acerbis Maier UFO Color Rite Plastics Plastics Plastics Paint Cyclecolor Replico Fairings Clearview Rifle Motorcycle paints Tengai fairings Windshields Windshields Bill Mayer Saddles Rick Mayer Cycle Corbin Saddles Custom saddles Saddles Manufacturers Final Drive Brakes Buchanan DID Diamond Chain Cycle Brakes Spokes and wheels Chain Chain Brakes Galfer USA EBC Brakes Braking Russell Performance Brake Pads Brake Components Brake Components Braided Brake Lines Manufacturers General Baja Designs Four Strokes Only Kisan Modulators Bel Ray file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 40 of 41 Dual sport eqpt Parts Headlight Modulators Chemicals Mikuni
21. 92046 1111 2x BM 2026 needle bearings KHI 92046 1110 1x BM 2015 needle bearing KHI 92046 1112 2x MHA 28 34 5 7F large seals KHI 92049 1181 4x MHA 20 27 5 7F seals KHI 92049 1109 e If you consider the Moose Racing swingarm bearing kit beware It only contains the bearings seals and shafts for the main pivot not for the linkage connection Chinese bearings are supplied and for 5 more you can order the OEM Japanese bearings from Ron Ayers or such Maintenance return to top If I do my own maintenance will I violate the warranty Thanks to the Magnuson Moss Act you will not violate your warranty if you do your own maintenance However you should maintain solid documentation See the links section for info on the act What tools should I take for roadside repairs You ll have to decide what makes you comfortable but a great starting place is the KLR Tool Wiki or look at the tools file What kind of motorcycle stand will work with the KLR The Larin lift available from Costco and Sam s Club works fine with the KLR Is a service manual available for the KLR There is a factory service manual available from dealers You need the base manual for the KLR600 and the KLR650 supplement for your bike s year Clymer now has a manual as well and it s reported to be very good Item ID M474 ISBN 0 89287 852 5 Do I need to keep this tube in the oil filter The metal tube in the center of the oil filter is a high pres
22. A video describing the valve adjustment process is available from Arrowhead Motorsports See also the links section for on line tutorials and shim calculation software What is the fastening torque for the XX XX bolt Here are the most popular torque values All numbers are ft lbs unless indicated Note that torque values should be hit while the bolt is turning to avoid static friction discrepancies en ogan Huka ge lower Engine sprocket old style 87 in lb Why do I get such a low reading when I try to do a compression test The KLR has the Kawasaki Automatic Compression Release KACR At low rpms lt 600 this device keeps one of the exhaust valves cracked open for easier starting This will prevent you from reading the full compression in the cylinder How do I get the fork seals out You can remove the fork seals without disassembling the forks by removing the retaining clip and then pressurizing the fork tube with compressed air Drain the oil first It may take a bit of pressure especially with OEM type seals but it should work How do I get the forks apart file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 33 of 41 The socket head screw in the bottom of the forks must be removed to get the forks apart If you have an impact wrench that will usually take it out If you are using a hex key the inner assembly will usually rotate and prevent you from getting t
23. Carb jetting affects combustion and thereby vibration Lean mixtures burn faster and cause more vibration backing the idle screw out a half turn can make a difference e Loose motor mount bolts are a common cause of excess vibrations Check the motor bolts on a regular basis and retorque per the service chart in the manual If the engine is run with loose mounts the vibration can damage the engine cases and mount surfaces In some cases it is possible to overtorque the bolts to the point that they stretch and the nut bottoms on the end of the threads rather than the engine mount The bolt will feel tight but the motor will just be floating The upper mount is the most important e Accessories like skid plates or exhausts can change vibration by changing resonant frequencies or redirecting vibration that would normally be absorbed by the frame Aluminum handguards can particularly increase handlebar vibration Check for interference points and correct as needed e It is possible to have a mis manufactured frame What happens is that the inside dimension between the frame bosses and engine cases is too large this results in the engine bolts reaching their normal torque spec before the engine case is clamped properly If you ve looked everywhere else to no avail try loosening the engine bolts up completely and examining the gaps between the frame bosses and cases if there is more than about 0 5mm 0 020 clearance with the bolt loosened there may
24. Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 35 of 41 The flat seat now appears to be a standard option You can also have the rear sides scalloped to make room for the grab handles In terms of material the basketweave is perforated and will let water through Best to use the vinyl and seal the seams with seam sealer or Nik Wax The contact was Raul Randariz Anecdotal warning Corbin will not accept returns If the seat doesn t fit or the stitching isn t up to snuff you may be stuck with it This has not been confirmed Note that since the saddles are custom they don t generally accept returns See their website for information Also It s a good idea to seal the seams One good product is McNett s Seam Grip but you must apply it carefully to avoid a mess e Russel Day Long e Sargent e Mayer saddles Continuing on the work of their father both Bill Mayer Saddles and Rick Mayer Cycle make fully customized saddles to the rider s specifications with the same materials and workmanship How do I reduce buffeting People find that the stock windshield is just the right height to dump turbulent airflow on their heads at highway speeds The quickest fix is to remove the stock windshield alltogether and see how that feels Taller windshields are also available a factory unit from Kawasaki and aftermarket units from Clearview and Rifle You may have to experiment with windshields d
25. In addition K amp N makes a gauze filter for the KLR Some people feel that the K amp N lets dirt through however inspection of bikes running K amp N filters show no dust on the inlet screen The downside of K amp N filters is that in very dusty conditions they can clog up solidly enough to stop the engine To avoid this a prefilter filter skin can be used These are stretchy covers that are oiled and placed over the filter When it s dirty pull it off and put a new one on or just run with the filter alone The skins are reuseable with washing and can also be used with foam filters See the links section for a comparative filter flow test Do I need that screen behind the air filter The purpose of this screen is unknown It could be a backfire arrestor or used to smooth airflow coming from the filter Some people remove this to increase airflow but no flowbench tests have been made to see if this restriction is signifigant compared to the filter Several people said the screen kept clumps of dirt from falling into the clean side of the airbox when they removed the air filter For that reason it seems like a good thing to keep How can I open up the airbox For maximum flow an L shaped opening can be cut into the top of the airbox underneath the seat If you prefer prefiltered air 1 diameter vents with foam inserts are available Mount them with the vent screen inside the box You can also cut the raised sections of the airbox door and
26. Page 1 of 41 KLR650 FAQ Last update posted 28 Oct 2009 Thanks again to all who have contributed B Model Tengai C model General Information Known Issues Engine Fuel Intake Exhaust Controls Electrical System Body Brakes Final Drive Wheels Tires Suspension Maintenance Off Road Gear Highway Gear Links The information contained herein has been developed by many riders over the years Thanks specifically to Marc Clarke for supplying his archives I haven t entered any data for the 2008 model unfortunately I haven t been able to keep up with the group very well and don t have one to examine myself Quick Links Need an answer Join and ask the DSN KLR650 Maintenance procedure repository Mark St Hilaire s site group Prefer a forum KLR650 net and KLR World Where is everybody Owners Map Other info that may be useful BMW F650 FAQ KLR650 Wikipedia Entry Parts Accessories Fred Hink Arrowhead Ron Ayers Bike Bandit Ebay KwikSpecs Front KwikSpecs Rear file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 2 of 41 KLR 250 Information Exchange This is intended to be a FAQ not a service manual or encyclopedia The service manuals are a good thing to have either the factory manuals or the Clymer book Please do not contact me asking for help with repairs bike advice info on different models etc I don t know it all I just collec
27. act Kawasaki Consumer Relations Kawasaki Motors Corp USA P O Box 25252 Santa Ana CA 92799 5252 949 460 5688 In Canada it s Canadian Kawasaki Motors 25 Lesmill Rd Toronto Ontario M3B 2T3 What do I do about the vibration Despite the engine counterbalancer a thumper still produces noticeable vibration The amount of felt vibration depends on the individual bike accessories added and even the subjectivity of the rider Some pointers courtesy Tom Bowman unless noted these apply to bikes in general not the KLR specifically e Mirror vibration can be improved by switching to XR650L mirrors order the whole mirror assembly which includes a vibration dampener see controls section and Bikemaster GP mirrors have also given decent results Ideally the rubber dampers should be tuned to move the mirror s natural frequency out of the KLR s vibration range You can also try Ken Sean folding mirrors e Another rider tried an extra set of ZRX mirrors that he had lying around and they worked as well Should be Kawi part numbers 56001 1564 amp 56001 1565 Thanks Ken e Installing aftermarket bar end weights can help Some have epoxied steel weights inside the ends or used RTV to seal in lead shot The Bar Snake is another option but has had mixed results Aluminum handlebars may also help see the controls section e Tire variables that can affect vibration include air pressure tread style balance and out of roundness e
28. al battery is a Yuasa YB14L A2 and there is a Die Hard equivalent at Sears WalMart also has inexpensive batteries Yuasa also makes a fully sealed AGM battery that is an exact replacement the YTX14AHL BS This battery comes with an acid pack that the dealer or customer activates when putting the battery in service WestCo also makes a sealed battery the 12V14L B For extra current and reserve capacity there is the Odyssey PC 545 gell cell non MJ version This battery must be mounted on its side to fit in the KLR battery box and you will have to extend one of the power cables The Big Crank AGM absorbed glass mat battery is another possiblity as is the WestCo Why does my headlight seem dim Some people feel that the wires connected to the headlight are too small and have replaced the wires with heavier ones or connected a relay to run the light Also keep an eye on corrosion in the connectors Check the condition of the reflector too On some bikes the reflective material has started flaking off so no amount of fiddling with wires or bulbs will help The only cure for that is a new headlight assy Can I use a brighter headlight bulb KLR owners often run a higher power bulb like an 80 100W 55 100 etc stock is 55 60 type 9003 H4 Your local NAPA should have the Wagner BP1210 H4 80 100 bulb for around 13 Some people have had problems with the headlight socket melting the NAPA LS6235 socket or one from an 84 Honda Accord is a cl
29. alled Pro Riding Secrets which offers tips on handling different offroad situations They also have reviews of adventure off road tour file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 6 of 41 companies and interesting articles on the past present and future of off roading They have even answered questions about KLR 600s and 650s in the Ask Dr Dirt section one was mine Last time I renewed it was a buck an issue At that price how can you stay away Update The September 2005 issue includes the KLR in a dual sport test ride and they even gave some love to the FAQ Thanks e Whitehorse Press is a catalog dedicated to motorcycle books and gear links How about movies KLRs have made a few appearances on the small and big screens There is a furry KLR in the last deleted scene on the Haiku Tunnel DVD One of the bikes near the end of The Fast And The Furious is suspected to be a modded KLR In Hackers Angelina Jolie s boyfriend carts her around on the back of a KLR The chief bad guy his girlfriend AND a kidnapped woman ride a teal white KLR in Cazador Del Serpientes e According to an article in UK s Bike magazine the behemoths in Judge Dredd were based around KLRs Can I put a sidecar on the KLR This has been done Adventure Sidecar Doug Bingham Side Strider Van Nuys CA 818 780 5542 Mike Braverman Sylmar CA formerly had sidecarmike com link
30. ame etc No Jack up the bike so the rear wheel is off the ground and slip a board under the tire to support it Disconnect the links from the bottom of the shock and remove the bolt at the top the nut is welded on the other side The shock can be dropped out through the underside of the bike What are the stats on the stock spring The stock spring is about 56mm 2 2 ID 254mm 10 long and the spring rate has been measured at 5 3 kg 300 lb NOTE Although the stock spring is 10 long the shock appears to be built for a 9 spring That is installing the stock 10 spring puts an inch of preload on it which is quite a bit The consensus is that you are better off with a stiffer shorter spring A rate of 450 Ibs inch seems to be ballpark for riders of 180 200 Ibs and 500 or 550 for heavier riders However you might want to consult a suspension specialist or the list for suggestions on your specific weight and riding style The proper diameter is 2 25 Where can I get a shortened shock to lower the rear The Hagons will custom make seat lowering monoshocks for around 400 Their US importer is Dave Quinn Motorcycles of Bethany CT 203 393 2651 See the links section for their link Also Progressive makes an off the shelf shock that will lower seat height about 1 5 How can I keep dirt off of the rear shock Moose Utility Division makes shock sock type of cover for ATV shocks part number MUD S38 fits the KLR There is also a product
31. ance and had good results on my ZRX and my re ringed KLR Purpose for the re ring was foreign object related There is not a big KHI conspiracy to make you do the wrong kind of break in so you have to come back for maintenance sooner Don t you think they d make more money selling more new bikes because they re known for reliability rather than making money on repairs Can I get a high compression piston So far we haven t found any way to get a higher compression piston other than custom manufacture Some have used sealant in lieu of the base gasket after cylinder overhauls which will give a minor compression increase The small change in cam timing doesn t seem to be a problem Update You can check Wiseco s European site for Tengai pistons Didn t someone make an oversize engine Steve Kesselring at Quality Engine developed a 750 engine conversion However this requires quite a few custom parts and is not available as a conversion kit The company does not do custom work for the general public but they do have lowering links and a few other KLR parts Check them out at Performance Design LLC There are also 685 cc and 705 cc kits developed by Cary at Schnitz Racing They require a post 96 cylinder to handle the larger pistons He can also clean up and improve your head Reports say that there can be a wait but it s worth it Where can I get my head cleaned up Cary at Schnitz Racing can rework your head and install larger valves i
32. ange it once you get out of the boonies You should be able to get 100 miles out of it If you re going on a longer trip adventure tour you may want to carry both sizes to save yourself the trouble of changing the tube twice How do aftermarket rims compare Rims by makers like Sun and Excel are much stronger than the stock rims You can order them and lace them yourself or have a place like Buchanan links build one with your hub According to the folks there Excel rims are harder to bend or ding but are more likely to crack Sun rims are easier to bend but also easier to repair What size are the axle nut cotter pins The stock size is 4 0x35 mm but you should be able to use 1 8 or 5 32x2 pins If you want something reuseable you can go with an R pin a k a hairclip cotter Why can t I tighten my rear axle completely See Rear hub bearing spacer in the Known Issues section file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 28 of 41 Can I use aftermarket wheel bearings The stock bearings are unsealed when they need to be replaced it is best to do so with fully sealed bearings These can usually be found at local bearing shops and are less expensive than the factory bearings Chinese bearings are generally of lower quality Ask them for the quality bearings such as Fafnir Torrington or Ingersoll Rand SKF bearings are less expensive and are reportedly strong
33. ant in low traction situations Also some have had problems with the slide carb someone tried the Mikuni kit and generally found that you can mimic stock fuel economy but have the engine fall flat on its face when you open the throttle wide Or you can go way rich make it run great and eat gas fast He dyno tested the bike and actually found a LOSS in HP He ended up going back to the CV carb Like I said spend your money on suspension For a milder stock replacement you can try a Mikuni VM36 carb you may need to trim down the intake side and if the carb was equipped for snowmobiles you will need to replace the float needle and seat with a set for gravity feed Exhaust return to top Why does my bike sound like an old VW This is affectionately known as tweety and can happen to bikes anytime after a few thousand miles It seems to appear earlier on bikes that are ridden on a lot of short trips thereby allowing condensation to remain in the muffler It also seems to be traced to clogging of the spark arrestor system The noise is merely an annoyance it will not damage your engine Aside from replacing the exhaust system you can try to fix it e Take a huge straightblade screwdriver like 12 shaft and sharpen the end with a file Look in the end of the exhaust there is a small perforated pipe running from the opening to about 8 inside It has a seam on the bottom 6 00 position that may already be split open Using the screwdriver
34. ariety of luggage is available from a number of sources Soft bags conform to the load and keep weight close to the bike assisting stability Soft bags generally require frames to support them off of the bodywork especially over the exhaust Hard bags are lockable Look at saddlebags and guards from Kawasaki Happy Trails Dual Star and others file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 36 of 41 Why did my right saddlebag catch on fire Heavy items should be placed in the left saddlebag especially if using lighter side racks The right saddlebag sits over the exhaust pipe and too much weight can push the side cover into the exhaust making for a messy situation What tailbags are available for the KLR The Kawasaki factory tailbag and the Rev Pack are both highly regarded Wolfman also makes the Alpha Pack which also features strong construction Has anyone tried the J C Whitney travel trunk Yes and it reportedly works very well What kind of tank bags are available for the KLR The Kawi factory tankbag is custom fit for the fuel tank and does not cover the gas cap Unfortunately the map sits somewhat low and the bag slouches into the sensitive zone if not packed full Also when people tug on the map window to look at the map the vinyl can tear at the stitches This can be fixed with Shoe Goo or E6000 Wolfman also makes a tank bag called the Explorer wit
35. ation with a fuel pump Some people have had success with the smaller brass or plastic screen filters but since there already is a screen type filter in the tank installing an additional fuel filter is not recommended Thanks Bryan K I run a brass filter and it doesn t seem to cause any problems However you should make sure the fuel lines are tight enough so they always slope downward Why does my bike run for a few minutes then stall e Your gas tank vent may be clogged When the bike stalls try opening the gas cap If air rushes in and the bike runs fine again your tank vent is clogged Clean the vent passage in the cap and make sure one of the tubes at the rear of the tank is open Preferably the red nipple should be capped off and the blue one should have a hose running to the bottom of the bike e The vacuum hose running from the carb to the petcock which ensures that fuel only flows when the engine is running is weak if it has the slightest kink it may close when it softens from the heat of the engine To fix either reroute the hose so it is as smooth as possible or preferably replace with a length of heavy wall fuel line What aftermarket air filters are best Several air filters are available Foam filters include the Moose Uni and Twin Air I ve seen one Twin Air filter that was too small for the filter basket and didn t have a hole for the screw Don t know if this was an isolated case or the wrong part number
36. be a problem This is fairly common on mass produced mild steel frames due to all the welding induced heating shrinkage e Specifically on the KLR it is possible for the chain driven counterbalancer to be out of sync Follow the procedures in the manual carefully it may take quite a few revolutions of the crankshaft before the alignment links are in the correct location One indication of this is if your vibration gets worse when you adjust the balancer tension What kind of gas mileage should I be getting Gas mileage will vary greatly depending on how your bike is set up For a rejetted bike running dirt file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 5 of 41 oriented knobbies it can be as low as 30 35 mpg On a stock bike with street tires 50 mpg is more typical and some bikes have seen up to 65 mpg This can also depend on where you are as gasoline formulations vary in different parts of the country How long will my KLR last Many people have the misconception that the KLR or thumpers in general will suddenly explode once it hits 30 000 miles I refer you to one member of the DSN list who reported the beginnings of piston slap At 80 000 miles Many owners have reached 60 000 miles without major maintenance and some bikes have broken 90 000 miles How much power does this thing put out Depending on the source values up to 48 hp have been quoted However
37. ble damping requires pulling the fork springs to change it The emulators can be installed without separating the forks by unbolting the damper rod bolt and sliding the damper out of the tubes Hard anodizing the fork lowers will also improve performance How do I adjust the rebound damping on the rear shock There is a little crescent shaped black plastic cover over the rebound adjuster at the bottom right side of the rear shock You have to pull that off to see the adjust thumbwheel It s p n 11012 CAP SHOCK ABSORBER in the Kawasaki parts diagrams It s not really obvious when you first look for it Note that it only should be turned in one direction How much air pressure should I use in the forks The forks will allow some amount of preload air pressure but are designed for atmospheric and this is best because it minimizes loads on the seals In fact you might get a plusher ride if you sit on the bike and then vent the forks through the valves If you need preload in the front it is best to put additional spacers over the springs Can I get inverted forks Sagebrush Machine makes adapters that will allow you to fit the inverted forks from a KLX 650 onto the KLR Also see the maintenance procedures in the links section for websites detailing fork swaps You can also use DRZ and KLX250 or KLX300 forks for the KLX you want the 43mm inverts Are cheaper fork boots available Daystar model 58 boots are made of a more resilient rubber
38. bottle it s fine Which brings us to the next question How much oil to put in The rated capacity is 2 5 liters which should put the oil at the top of the sight glass However this usually puts the level over the top possibly file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 10 of 41 due to residual oil in the passageways Some owners insist that the sight glass is mounted too low in the engine case and add 10 oz beyond the upper fill mark Others insist that the sight glass is correct one even going so far as to contact KHI for the straight dope KHI engineers insist that the sight glass is in the correct location Running with too little oil can cause problems but so can running with too much In practice owners running their bike either way don t seem to have any problems Paying attention to your oil level and keeping it at the top of the glass is probably the best compromise As for oil change frequency most people change their oil at 1 000 to 2 000 mile intervals depending on riding conditions The only way to truly develop an oil change schedule is to have an oil analysis done at different intervals while riding in your typical fashion conditions When can I start running synthetic oil Common lore is that you should run regular oil for the first 3 6 000 miles on a new engine or after rebuild and synthetic is fine after that Which is the best oil filter Se
39. ck bars have a hole drilled on the clutch side to position the control cluster via a pin When switching to aftermarket bars it is best to just grind the pin off of the cluster so it can rotate if the mirror is whacked file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 18 of 41 Why has my tachometer gone all wonky The tachometer is electrical and is driven off of the ignition control box If it starts behaving erratically check all electrical connections related to the ignition If problems persist your ignition box is probably going bad Cheap it isn t Sorry Why doesn t this replacement temperature gage work If you happen to replace your temperature gage with a unit from a KLR 600 the gage may pin at hot shortly after starting the bike You can fix this by installing a 3 4 ohm resistor Kawi p n 28018 1052 in line with the gage Be sure that your bike isn t actually overheating of course Why doesn t my speedometer work There is a washer in the front wheel hub that connects the hub to the speedo drive gears it has tangs on the outside and inside It is possible for these to break off rendering the drive nonfunctional In particular make sure you get these lined up right with the hub when installing the front wheel If you tighten the axle nut and the front wheel no longer spins freely you may have compressed the drive tangs against the hub Do any bicycle spe
40. cure is to back out the idle mixture screw a bit and shim the stock needle up 0 020 with a washer See the Fuel Intake section for more info Rear brake pedal bracket prone to fracture The bracket that mounts the rear brake pedal to the frame is an aluminum casting a number of people have seen them break if the bike is dropped and the bracket hits a rock or even if a large rock is thrown up against the brake pedal Dual Star makes a machined bracket that should be much stronger than the stock unit Headlight fuse tends to blow If the headlight switch pauses between hi and lo it is possible for both filaments to be on at the same time This will overload the 10A fuse This can be fixed by upgrading the fuse to 15A What happened to my license plate If the rear suspension is bottomed out the tire can grab the bottom edge of the license plate At the least this will fold over a little lip at the bottom of the plate at worst it will tear off the rear inner fender and leave it on the trail somewhere This is most likely when using a taller knobby or when using a smaller countershaft sprocket or an older chain as the rear axle will be moved further back when the chain is adjusted One solution is to bend the bottom of the license plate back away from the tire Better is to move the bracket up Remove the reflector located above the license plate and install the bracket on that part of the fender the reflector pad is just wide enough for th
41. dures including valve adjustment General mechanical and electrical engineering info Big Cee Engineering CVK40 carb pictures and description very thorough KLR600 transmission mod kickstarter and more Building a tool tube Mark Converting the turn signals to 1157 dual filament bulbs Krokko Laser Pro Duro writeup John Lyon Changing a flat tire Cycoactive 2 There is a big writeup of engine mods with dyno runs at Patman racing Comparison of air filters krokko Wheel lacing information Wheel Works Buchanan Sheldon Brown Making LED turn signals work Custom Dynamics Installing inverted forks Zach Fork seal replacement 1 Stock shock rebuild Calgary DS Carburetor tuning tips Mikuni Troubleshooting electrical systems ElectroSport nee Electrex Handlebar comparison How to tune your suspension strappe Finishline West has a number of illustrated procedures and accessory reviews Jay has a video version of the valve adjustment procedure Proceeds go to a good cause UFO Superbike low front fender installation Lujo Airbox Mod How to report a balancer failure courtesy Professor Jim Hyman file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 38 of 41 e Methods to remove smog equipment are 1 and 2 e Electronic circuits to play with 1 2 e Magnuson Moss Act Owner s Pages These pages have
42. e bolts For the ultimate solution remove the bracket completely and bolt the plate directly to the outer fender below the taillight Note that legally you will probably have to supply lighting for the license plate it is possible to cut a rectangular section out of the bottom of the taillight lens and glue a piece of clear plexiglass in place to seal the lens It may also be illegal to move the plate or remove the aforementioned reflector Dealer screwups If you buy the bike new the dealers often leave the forks in the shipping position with the fork tubes extending about 3 beyond the top of the triple clamp The tops of the fork tubes should be flush with the top of the triple clamp Shift lever breakage Many riders have seen the stock shift lever break at the base weld This doesn t always happen but you should at least remove your stock unit and inspect the quality of the weld If the weld looks complete and full you will probably be OK If not you can either have the weld redone or better yet replace the shifter with a Moose or IMS unit These units though can show wear in the splines Examine the shifter for play occasionally and tighten the clamp bolt as needed Note that the IMS unit is about 3 4 longer than the stock unit I think the Moose is about the same as stock The extra length can be handy file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 9 of 41
43. e to remove it Very easy to wreck the thing Sometimes a quiet core can be punched out using a hammer and a broomstick into the baffling If you can t tap out the core using a piece of wood get an automotive dent puller remove the discs grind punch a small hole in the perforated tube in the core and use the dent puller to remove the core When you reassemble the muffler use anti seize EVERYWHERE that metal meets metal Controls Instruments return to top What can I do about handlebar vibration Various methods used to minimize handlebar vibration include filling the bars with steel shot and or latex caulk using end weights and installing soft grips Using a handlebar with no crossbrace can help too but will be more suceptible to bending if the bike is dropped Can I get the stock grips off in one piece Probably not The original grips are the one factory installed part that I can guarantee will not fall off due to vibration Many people resort to cutting and scraping them off See the next question for replacements What replacement grips are available Progrip 714s are popular for vibration reduction grips won t cure it all but they can help To remove file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 17 of 41 old aftermarket grips you may just be able to squirt compressed air under them and float them off To install the new grips you can use grip glue
44. e website klr 10 27 2009 KLR650 FAQ D607R 130 80R 17__ Meizer fourm 90 90H 21 S88 FTourance RR 130 808 17 sss Michelin Toor 0 908 21 s T6oR__ is0 80 R 17 _ S8s Spero T 585 MCE Karoo p090R 21 Meier Sahara 3F 90 21 fess Sahara R_b0ROT 77 Js MCE Karoo R 130 80R 17 M22R 5 10x17 NOTES MB Mount Backwards Tire comments file C Documents and Settings J Christopher Krok My Documents BigCee website kIr Page 26 of 41 10 27 2009 KLR650 FAQ Page 27 of 41 For a comprehensive website on tire choices see Mike Silverstein s web page How do I keep my new tire from rubbing on the chain guard The chain guard is only held on by a stamped sheet metal bracket Just bend it out of the way Do people use the Harbor Freight tire changer The HF tire changer does work although some people have trouble with the included tire iron One option is to purchase the tire iron for a Coates 220 tire changer Costs more than the whole HF changer but has plastic tipped ends and works much better Also note that the rim grips on the HF unit are too narrow for modern sportbike rims if you re planning on using it for other bikes Do I need rim locks For serious offroading rim locks can be used to keep the tire from rotating on the rim and thus removing the valve stem This is generally only required at tire pressures under 20 psi and some have ridden pressures as low as 14 psi without locks Also
45. eakers These are available in auto parts stores e Cut the wires to the fuse box and extend them to the fairing or behind the coolant bottle and add a fuse block Body return to top Is there a paint that matches the silver on the frame Dupli Color WP101 Silver high performance wheel paint formerly known as Steel is a good match although it may be a bit more glittery than the stock paint KRYLON 1402 Hi Temp Aluminum also matches if you want to paint your exhaust or heat shield How can I paint my plastic Krylon Fusion sticks direclty to plastic but it is very sensitive to solvents and gasoline even after drying for a month or more It does much better if you topcoat it with urethane clear coat with flex agent The best bet may still be plasticizer additives to regular paint and an adhesion promoter such as Bulldog ETPO 123 This has proven to give good results For black bumper trim paint may also work Where can I get matching paint Color rite has it just follow the steps Since the tank is the only thing painted that s the color you ll find The plastics may or may not match the tank depending on the year of your bike How do I restore faded plastic There are several options You can heat it carefully with a heat gun This is especially good for removing white spots from bends or kinks A hair dryer can also work and is good on older plastics that need more heating as the hair dryer is less likely to overheat
46. edometers work with the KLR The Sigma Sport BC800 Planet Bike 9 0 and the Panoram bicycle model have all been successfully used Get one with a rear wheel pickup these have longer wires that should reach the front wheel without splicing Wireless models won t work with interference from the ignition Electrical System return to top How much power does the charging system put out Older models 14V 14A 8000 rpm above redline newer models 14V 17A 7000 rpm We are unsure as to when this change took place but the only part change seems to be the rotor new p n 21007 1283 You may be able to upgrade your charging system by switching to the newer rotor but this is unconfirmed The normal electrical load is around 9 amps for the headlight tail and license lights instrument lights The ignition system has its own supply coil and does not drain the main charging circuit Then are the occasional loads like the cooling fan turn signals brake light etc Generally the KLR can handle at least one high power accessory like a high wattage headlight heated grips heated vest etc It can handle more if you re keeping the rpms above 2500 and not stuck in stop and go traffic all of the time The best way to tell for sure is to connect a voltmeter and keep an eye on the voltage while you are riding under different load conditions A Heatroller is a good idea too as you seldom need full power from any heated item Can I upgrade the c
47. el pegs 1995 or equiv which fit right on the KLR brackets You need 1RH front footrest 43550 44B 10 019 1 LH front footrest 43560 44B 10 019 and 2 springs 09448 15008 The Kawi pins will work fine although they are a little smaller in diameter than the DR pins If you want to use the DR pins p n 09200 10008 2 req d you will have to drill out the KLR peg brackets e In 1996 Suzuki widened the footpegs if you want the wider ones you need One 43550 14D30 footrest One 43560 14D30 footrest Two 09448 15004 springs Two 09200 10013 pins e IMS Super Stock and Pro Series pegs probably the priciest but most aggressive These are higher than the stock pegs which could make shifting difficult You can rotate the shift lever up one notch on the spline or try an IMS shift lever which is longer than stock Ok so where do I get better passenger footpegs Passenger pegs from a DR350 will fit Where do I get a better skid plate Utah Sport Motorcycle makes the most popular skidplate for the KLR In addition to selling direct their file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 34 of 41 skidplates are sold by Moose MSR and Happy Trails White Brothers has theirs made elsewhere The problem is that USM now trims their plates for use with centerstands this leaves the rear of the engine case unprotected Happy Trails can weld an extension back on as well as add a second
48. epending on your height so it is best if you can try a friend s before you buy one yourself How do I keep from getting blown around on the highway People have had good results with removing the stock front fender and mounting a UFO aftermarket fender right over the wheel as on street bikes The smaller fender blending in with the front wheel reduces the wind s ability to tweak the front end Also check to make sure that your steering bearings and fork tubes are properly set If you have sloppy forks a fork brace may help How hard is it to mount a low front fender No fender is made specifically for the purpose so it will take some tweaking If you re going the supermotard route a KTM supermoto fender will bolt to a K 9 fork brace over an 18 wheel with no modifications The stock wheel is 21 A 19 wheel requires longer spacers on the fork brace How do I reduce high speed wobble There are several things you can try e Increase preload on the front If you raise the rear relative to the front i e through preload adjustment you change the steering geometry and can induce wobble e Check the tightness of your steering bearings e Check your tire pressure to make sure it s too low 32 psi seems to be a good number for front and rear e Fork braces and lowered fenders have been proposed as solutions but these address external effects like wind and road condition What kind of saddlebags are available for the KLR A wide v
49. eplico links makes aftermarket fairings for about 450 US shipped from Australia you will need to weld two mounting tabs to the top of the fuel tank and repaint it How do I get the seat off Remove the two side covers and you will see the two bolts that hold the seat down After removing the bolts pull the rear of the seat up and then pull the seat to the rear to unhook it from the tank If you don t want to have to pull the side covers off every time you can cut holes in the side covers over the bolts to get at them directly Where can I get another fuel tank IMS makes a couple of different plastic replacement tanks for the KLR the 5 5 gallon and the 6 6 gallon military tank part 113121 used on the USMC diesel KLR which has the shrouds molded in Some people refer to this as a 7 gallon tank but the volume range is due to production variances IMS may not list this tank on their web site but they will make it on special order You can specify any color they use Black B1 is supposedly best for sweat resistance the fuel s not yours there is also green G2 translucent green G3 white W1 and natural N1 They also may have a coating that prevents fuel sweating Here s the kicker thanks to Walt Lesnowich When you get a military tank you are actually getting the commercial version of the military tank The bonafide military tank has a different gas cap with a check valve in the vent to prevent leaks The commercial version
50. es file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009
51. f desired Worth the wait Getting a proper three angle valve job from your local shop may be worthwhile as well I don t know if all KLRs are the same but my valve seats were just a single cut Are there any alternatives to Kawi valve shims The KLR s valve shims are 29mm in diameter There are other sizes that are close but make sure they give you the right ones If your Kawi dealer doesn t have the right ones in stock shims from an 87 BMW K75S and 82 Yamaha Seca 750 are the same diameter Beware there are also 29 5mm shims which will not work I fried my head What do I do If your cam journals are scored or chewed up for whatever reason Engine Dynamics of Petaluma CA might be able to repair the head They will resurface the cam and rebuild and finish the journals to match the new cam diameter What if I break the cooling fan If you drop the bike on the left side the radiator fan shroud can get bend and stop the fan The motor shaft then spins in the fan and melts the hub Apparently the hub can also melt if the fan isn t jammed The fan can only be purchased as an assembly which is expensive Muzzys makes an aluminum replacement cooling fan with a steel hub that is immune to this damage However over the long term the hub crimp on the aluminum unit can also loosen allowing the blades to loosen It is also possible to epoxy a melted plastic hub back together What kind of coolant can I use Any silicate free antifreeze m
52. h a large capacity and a sloping bottom to help it match the KLR s tank This bag must be moved to access the gas cap but apparently it is easy with practice and the bag is quite popular How do I read my map in the dark Aerostitch makes illumination panels and you can also try the Lightwedge which is available at many bookstores What tank panniers are available for the KLR Aerostitch makes two sizes of tank panniers Your legroom will determine which is best To mount them the cross straps must be cris crossed over the main frame spine in front of the tank Wolfman and Dual Star also make tank panniers Can the tail rack be improved Aluminum plates that mount over the tail rack and increase its surface area are available These include the Top of the Line Rack and a rack plate from Dual Star Are there any locks other than Kryptonite Abus locks are available from Lockitt Can I get a center stand Center stands are made by Mo Tec Dual Star and Five Stars You can also order them from Arrowhead Links return to top Further Information e The MADS KLR650 mailing list is an anything goes KLR list at Yahoo Groups e The DSN KLR650 mailing list at Yahoo Groups If the FAQ doesn t have it check the archives or ask the list It is all knowing e Find out where to go or talk about where you ve been at AdvRider file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR
53. harging system Electrex makes a higher output stator G45 make sure you re getting the newer thinner one and rectifier regulator RR26 If you upgrade the stator you should also upgrade the R R Installation requires cutting the wires on the stock stator and threading the new ones through the grommet The output of this combo is claimed to be 280 watts but this hasn t been confirmed What voltage should I see at the battery The no load voltage is around 12 9 V so anything less than that while the engine is running means that the battery is discharging Why won t my bike start file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 19 of 41 Many things can prevent your starting system from working But nine times out of ten it s just a bad battery connection Check the wires make sure they are securely attached to the battery and the screw isn t bottoming out in the slot before it reaches full tension and make sure the faces of the ring terminals and battery terminals are clean With a loose connection it s possible for your lights to come on when you turn on the ignition and dim out with no starter cranking when you hit the start button Basically bad connections limit the amount of current that the battery can supply the starter has such a low resistance that it will draw all of the current at the expense of other loads The second culprit is a bad battery E
54. has a rubber baffle The cap sizes are different and not interchangeable between the two tanks It appears that Dual Star is the only dealer that can provide the true military fuel tank What is this rubber hockey puck I just found on the ground The front of the fuel tank is supported by two rubber bushings that sit on posts on the frame It is possible for these to fall off while you are sliding the tank in place Attaching them with a drop of E6000 or Shoe Goo will keep them from falling off next time Does anyone make a cover for the KLR Any larger cover should work Tour King makes a cover for the KLR but I m not sure if it s specifically for the KLR or just a model that fits WalMart has the Wolf cover for just 20 and again large seems to fit best XL might be preferred for very long term storage though What if I want to install smaller turn signals The minimum legal distance between turn signals is 16 inches in the front and 9 inches in the rear Minimum edge to edge separation from centerline of headlight and taillight is 4 inches The federal regulation is listed in 49 CFR 571 108 file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 23 of 41 Brakes return to top What kind of brake pads should I use One of the Galfer staff is a KLR owner and recommends the following Galfer pads 50 50 on offroad Galfer green front part FD091G1532 FDO75 sintered
55. has much more reserve power and can keep the current flowing as the short heats up This will be even worse if you have the car engine running Fan and starter safety replacement Toyota part number 90987 02004 83 is a plug in replacement for these relays for about half the price of the Kawi unit and usually available from dealer stock It is also listed as NAPA Beck Arnley P N s BA2030055 2030055 Where can I find a wiring diagram There is a wiring diagram in the factory shop manual and probably in the Clymer manual However Professor Jim Hyman took the time to develop a comprehensive full color wiring diagram Mark B highlighted the fan circuit Left click to view right click to download gif jpg Fan circuit printing instructions Where are the fuses The main and headlight fuses are in a black plastic box under the seat and over the battery The fan fuse is next to the coolant overflow tank behind the shroud on the right side Why is my battery running out of water Vented batteries typically lose water over time via electrolysis during recharging In hot weather the water level will go down faster However rapid water loss in a battery can also be a sign of file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 20 of 41 overcharging Check the voltage going to the battery to make sure your system is OK What replacement batteries are available The origin
56. he handlebars to make sure the forks are free and retighten Make sure your headset is tight too Also the height relationship between the front and rear suspension can affect steering stability If the rear is made higher new shock increasing preload etc it may make the steering unstable This can be corrected by increasing preload in the fork by adding spacer washers Or try to lower the fork in the triple clamps For extra stability Eldon Carl has designed fork tube extensions that allow you to lower the fork further Note that increasing stability reduces maneuverability so you must arrive at a balance of the two What are the dimensions of the stock handlebar For comparison to other bars here are approximate dimensions of the KLR handlebar thanks Matt Center What aftermarket bars are available for the KLR Aftermarket bars are a much better option than factory replacements Steel bars are available for around 20 40 and 85 will get you quality aluminum bars Many people like the Renthal 666 desert bend which is comparable to the stock bar but wider as is the CR Hi If you need something taller ATV bars are a good way to go i e Renthal Suzuki Quadracer or Yamaha Raptor MSR Dominator etc Taller riders may want something with less pullback than these Note that you can also get some adjustment by simply rotating the stock handlebars You can also move the bar up and back with risers links Note that the sto
57. he screw out There is a special tool to hold the inner assembly but you can make your own Cut a piece of 5 8 threaded rod 17 5 long Affix nuts flush on both ends either by welding or by putting two nuts on and jamming them together Insert this into the fork tube and it will engage the inner assembly Use a wrench to hold the upper end Or instead of putting a nut on the upper end weld a T handle on Which tool to I use to remove the magneto The magneto puller listed by Motion Pro is NOT the correct one for the KLR although they are beginning to rectify this The proper unit is M22x1 5 K amp N also makes an M22x1 5 magneto puller p n 82 0170 but does not list it for the KLR When using the magneto puller put anti seize compound on the threads and nose and tap it with a mallet as you tighten it How do I keep track of my meticulous maintenance Why you can download these handy service logs Print them out fill them in and stick em in a binder There are pdf versions for general use and an Excel file containing the original version of the files in case you d like to customize them Master File Service Log Valve Check 1 cyl Valve Check 4 cyl Off Road Gear return to top Where can I get better footpegs The stock KLR pegs are good for the road but get very slippery offroad when wet or muddy There are a few options for replacements e KLR250 pegs a cheap option if you can find them from a salvage yard e DR650 ste
58. hewed up Sagebrush Machine Shop makes a stronger replacement part that gives full engagement of the splines rather than half e 1996 and later bikes have a nut 27 mm hex or a 1 1 16 socket can be used with retaining washer First flatten the folded parts of the washer Then remove the nut An impact wrench is superior for removal If you have to remove it manually use a 1 2 drive with breaker bar and step on the rear brake to lock the sprocket i e while the chain is still on Is there a better nut for the countershaft sprocket on 1996 bikes This is a fairly standard thread size for countershafts The nut from a 1983 Suzuki GS1100E will work and the nut from a Kawi ZRX might work as well These nuts have a full height hex rather than the stepped design of the KLR nut This may give you a better grip with the socket Sagebrush Machine also offers a replacement nut Wheels Tires return to top What tires should I use The table below lists popular tires for the KLR The street dirt split is only approximated By popular request I am including a few street only tires I do so reluctantly because using a KLR as a street only bike is sacreligious unless you supermotard it The standard KLR sizes are 90 90 21 front and 130 80 17 rear Use of other sizes may cause interference so be careful Price ratings lt 50 50 100 100 ee ee ee file C Documents and Settings J Christopher Krok My Documents BigCe
59. ifference in bodywork the front brakes are better dammit and the suspension is an inch or so lower The C model has major differences outlined here How does it compare to the KLX The KLX650 is much more dirt oriented with inverted forks lighter weight a smaller gas tank and different engine Better than the KLR on the dirt but not as capable on the highway For more info on the KLX visit their mailing list in the links section How has the KLR650 changed over the years No one will ever accuse Kawasaki of applying kaizen to the KLR production line Aside from the paint job not much has changed since it was introduced in 1987 The key mechanical differences are per Eldon Carl e 1987 Crankshaft is unique to this year e 1988 Beefed up the engine cases with extra bolts between the crank and countershaft crank has a different part number and may be lighter e 1990 Countershaft improved with longer splines for increased engagement with sprocket e 1992 Changes to front brake master cylinder e Mid 1996 Changed valve cover added bracket to hold cam chain bumper changed crank to heavier unit improved clutch basket with more clutch plates changed countershaft sprocket retainer from slotted plate to large nut changed 2nd and 3rd gear ratios Kickstarter no longer fits with new clutch basket New left balancer weight sprocket begins with engine KLE650AE032206 e Service manual indicates higher charging system out
60. ine If anything later bikes seem to be more prone to failure perhaps because of the change to solid balancer sprockets If this system fails and the balancer chain jumps it can sieze the engine Eagle Manufacturing makes a machined adjuster arm available from Arrowhead that is vastly superior to the stock unit Both units are of equal quality although they offer different spring lengths In addition the adjuster bolt and spring were upgraded in 1996 earlier models can be upgraded by replacing the bolt and spring and adding the washer The required parts are Idler spring 92144 1860 7mm O ring 670B1507 washer 92200 1263 idler adjuster bolt 92150 1923 See the links section for a way to report balancer failures Starter circuit fails to work or only works with in neutral with clutch out Engine runs in neutral but dies when I put it in gear There are two known causes for this First the side stand switch can corrode and sieze up or get bad contacts It is best to bypass this switch before it goes bad and leaves you stranded in the wild To do so simply disconnect the connector at the switch under the small black plastic cover and short the harness wires together brown and green white with a jumper The second part is the clutch safety switch at the clutch lever which tends to fall out of adjustment To bypass disconnect the plug from the clutch switch underneath the cover on the instrument panel Short the black yellow and b
61. ixed with distilled water should be fine If you want something pre mixed Rotella 50 50 will work and Honda and others has a mix available at motorcycle shops Note that if you live in a warm climate you might be better off with 30 anitfreeze water is a better conductor of heat and you ll still have adequate high temp protection file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 12 of 41 Can I improve cooling You can improve airflow to the radiator by going to a low mount fender up to 15 degree improvment and by filling the gap between the radiator and tank shroud You can also improve cooling system performance by switching to an automotive style thermostat with a Thermo Bob housing This housing also does a much better job of keeping the engine properly warmed up and regulating the temperature in winter conditions If you re having serious cooling problems you may want to check the water pump impeller shaft it s only three bolts to take off the water pump cover The impeller shaft can break if the nut is over tightened and a few people have removed the cover to find the shaft already broken off What about the hoses If your hoses are cracked or just old factory replacements run around 60 for the set However you should be able to cut all three pieces from a Goodyear 63936 heater hose which has some pre formed bends which is closer to 25 Is an aftermarke
62. lding yourself over the seat from the right side placing a wrench on the rear axle nut and then pulling up on the wrench with your left hand like you re trying to tighten the nut This should give you good compression Check the chain for slack with your right hand Is there a better chain guide available Fredette part no 01 013 88 93 KX s 91 93 KDX 250 s 89 93 RM s amp RMX s can be fitted although file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 25 of 41 you will get a stronger mount if you can make an adapter block and put a second hole in the swingarm It also seems to benefit from a 1 16 spacer alongside the upper nylon block The chain guide also goes under White Bros part 45 013 Where did my chain adjuster swingarm cap go If you don t thoroughly counter tighten the nuts on the swingarm caps they can work themselves off and you will lose the cap If the axle is tight this is not an immediate problem and can be temporarily fixed with fender washers To avoid this problem repace both nuts with a single M8 nylon insert locknut Note that these are generally 13mm hex which is not included in the stock tool kit you ll have to pack something How do I replace the countershaft sprocket e On 95 and earlier models two hex head screws hold a slotted retaining plate Remove the screws rotate the plate and pull it off Note that the retaining plate can get c
63. lue red wires on the main harness with a jumper In both cases the switches can be reactivated by removing the jumpers and plugging the connectors back in It is also possible to bypass both at once by bypassing the starter safety relay This is not the main starter relay but an adjacent secondary relay that is used to manage the safety circuits Remove the relay and connect either of the yellow red wires to the black wire or use the yellow red wire from the small relay to replace the black wire on the starter relay The starter safety relay has the same part number as the fan relay so hang on to it they re not cheap There are reports that one of the safety file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 8 of 41 circuit diodes still needs to be grounded for the neutral light to work properly you can do this by bypassing the sidestand switch It also appears that the running safety circuits can be bypassed by grounding the red black wire coming from the CDI unit but this has not been confirmed Weak front brakes The front brake on the KLR is pretty weak particularly for heavier riders and loads This is actually somewhat useful in the dirt but can be bad news on the street See the Brakes section for upgrades Lean Jetting The KLR is jetted very lean from the factory This can manifest itself as surging when cruising at medium throttle or 3 4 000 rpm A quick
64. material and cost about one fourth what the stock units do Are fork braces useful On the street riders have found a great improvement in handling by adding a fork brace The bike tracks much better through turns Off road feelings are mixed While it does seem to keep the front end from wallowing so much in sand and prevent it from picking up other lines it also causes every bump to be transmitted to the handlebars rather than be absorbed by fork flex Fork braces are available from Happy Trails Arrowhead Dual Star Kytech Scott Summers and others How can I beef up the rear suspension If you weigh over 150 lbs you could benefit from a rear suspension upgrade For reference the stock spring is 10 long and 300 Ibs inch Replacement manufacturers are e Progressive suspension makes a replacement spring which can make a big difference The 500 560 spring is p n 1159 20GT and may have to be special ordered It is technically a replacement for their 420 shock but works with the KLR shock It doesn t match the spring perches exactly but that doesn t seem to hurt anything Note that the stock shock doesn t really have enough rebound damping for a heavier spring but people get away with it e Eshocks sells springs and makes a 9 spring that will fit the KLR shock If you re lighter you might like this spring as you can get a better preload adjustment e Progressive also makes the Larry Roessler 420 series shock Note that this shock ca
65. n not be revalved and can only be rebuilt by Progressive e Works Performance offers a variety of services All of their shocks are made to order and tuned to match the bike and the rider s weight riding style and skill level If it doesn t feel right they will retune it for free if you return it within 30 days At the low end they do a heart transplant wherein they take your shock and put Works Performance guts in They also make full shocks with the Ultracross at the top end offering an external reservoir and adjustable preload and file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 30 of 41 rebound damping e Cogent Dynamics makes the Moab shock for KLRs if you speak to Rick he can help you customize it e Ohlins makes a quality shock but at last check they were no longer imported to the US You must make arrangements to have one brought into the US as of this writing They will pick a spring rate to match your weight but most people have the shim stack redone after they receive the shock e Gary at GPS Suspension can rebuild revalve the stock shock and can build a works shock for you the link to GPS has changed so I m not 100 sure this is the same outfit e WP owned by KTM also makes a shock which has ben well received e Cogent Dynamics now makes the KLR 650 Moab shock To remove the shock do I really need to remove the battery subfr
66. nch the nut off the entire way With the standard nut you only need one wrench to loosen it and you can spin it off the rest of the way by hand What size are the axle nuts Front Nut 22 mm axle head 17 mm Rear Nut 24 mm axle head 19 mm What size are the spoke nipples 6mm Suspension return to top How do I reduce brake dive How do I keep the front end from bottoming You can increase fork preload by replacing the stock spring spacers with longer ones the stock ones are 1 12 in diameter by 5 5 long 3 4 PVC pipe works as will other pipe tube materials Use a pipe cutter so you get a square cut Replacing the fork springs with Progressive Suspension Larry Roessler series units part number 11 1151 gives a much nicer front end The springs are longer than stock and the spacers are cut to 2 so the initial travel is more plush They are progressively wound so they get stiffer as they are compressed Note that Progressive also makes a standard non LR p n 1128 replacement while these are still an improvement over stock the LR units are much better Also consider changing the fork oil The standard oil is 20W 10 but most aftermarket oil is single weight only 20W is too stiff for most people but 15W and 10W are good The next step up are Race Tech file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 29 of 41 Cartridge Emulators which give you adjusta
67. now inactive Sidecarcross Will AAA tow my bike For AAA bike towing you need to add RV coverage not the plus coverage There is also a question of wether or not they will do this in all states AAA will also tow bikes as part of their motorcycle insurance policies be sure yours includes it Other options are AMA MoTow service and MTS Towing links How do I respond when accosted by anti accessers Harry from SC relates this story A few years ago I was riding a trail around Colorado Springs I pulled over and stopped as I came apon two young lady hikers One screamed You should be on the road and I said You should be in the kitchen I ve still got the helmet with the big dent in it where the rock bounced off What is a DPO Dipshit Previous Owner i e the idiot responsible for all of the damaged threads missing parts and hacked electrical connections on the used KLR you just bought You don t notice these problems immediately of course What is the airspeed velocity of an unladen swallow European or African Known Issues return to top file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 7 of 41 Fork oil level Error in some shop manuals A few versions of the shop manual call for the fork oil level to be checked with the forks extended This is incorrect The fork oil level should be checked with the springs removed and the fork tube fully
68. ose replacement and is made of heat resistant Bakelite Others however have ran these bulbs with the stock socket and wiring with no problems The one thing you definitely want to do is replace the 10A headlight fuse with a 15A one What size are the instrument bulbs Turn signal and neutral lights are 24 the hi beam and three gage illumination bulbs are 194 To change these you don t have to remove the instrument cluster you just pull out the rubber socket and the bulb will be in it What are the two loose wires behind the fairing The Brown white and black yellow gnd wire pair are for the city light circuit on European models These wires come on with the ignition and can be used for an accessory The city light only draws 4 W but people have used these wires for heated grips with no problems and those draw nearly 48 W Why aren t my aftermarket turn signals flashing The stock flasher needs a certain load to activate The bulbs on some aftermarket turn signals don t draw enough power to trip the flasher You can correct this by going to a variable wattage flasher such as the Tridon EL12 Are there brighter taillight bulbs The 1157 bulb in the taillight socket can be replaced with a 2357 The tail light is the same but the brake light is 25 brighter with only a 2W power increase The downside is that the brake light filiment of the 2357 has a life rating of only 400 hours while that of the 1157 is 1 200 hours Both b
69. plate to the bottom for real abuse Dual Star also makes a skidplate but it doesn t come up as high in the front As a result you may need to add one of their water pump guards The Utah plate covers the whole water pump Can I protect the oil drain plug The drain plug sticks out past many skid plates Dual Star makes a low profile version and you can buy a Moose magnetic plug and trim off some of the hex There is also the Greenline 73000H 12 How can I protect the radiator If you drop the bike on the left side the only thing supporting the tank shroud is the radiator This can damage the radiator as well as the cooling fan Guards are available that mount under the tank shroud and protect the radiator Two different units are made by Happy Trails and Dual Star respectively Can I replace the stock handguards with something better Aluminum handguards are a great improvement Maier Woods Pro Deluxe p n 59525 if you have fat bars you will need p n 595340 as well will fit without cutting down the ends of the clutch brake levers The plastic wind deflectors must be ordered separately black p n 595340 other colors available Another option is the Acerbis Rally Pro although they are a bit lighter and may need to be bent back after a crash Avoid the Rally guards with integral turn signals they don t have a metal reinforcement and can bend enough to break levers Other options are Moose Enduro Engineering and Tusk guards Tusks a
70. put only part number change is the rotor The new power rating is 17A 14V 238 W 7000 rpm the earlier one was 14A 14V 196 W 8000 rpm yes above redline e 2001 Assembly shifts from Japan to Thailand Hard to say if there are any quality issues as the parts still seem to be manufactured in Japan e 2007 New shift lever There must have been more changes If I e mail you you ll give me the secret list of other changes right Dream on Although in 2006 they offered it in two color schemes for the first time What year is my KLR The frame sticker shows the date of manufacture The model year for all cars and bikes sold in the US is indicated by the tenth digit of the VIN this is an ISO standard and is becoming more widely used M 1991 N 1992 P 1993 R 1994 S 1995 T 1996 V 1997 W 1998 X 1999 Y 2000 1 2001 2 2002 A 2010 What is this An people keep mentioning This is a letter code that indicates the submodel and year of the bike A bikes are for the US market B file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 4 of 41 is the Tengai and C is the Canadian European model The number n represents the year of manufacture with 1 as the first year An L at the end of an A designation means that it is a California bike with a smog cannister The first year of the A model was 1987 so an ASL is a 1991 California spec US bike How do I cont
71. re very inexpensive and available from Rocky Mountain ATV links Are there better tools I can carrry The stock tool kit is OK but you might be better off putting your own together Dual Star makes nice laser cut wrenches that will work the axles and other bolts Also the single 17x24 mm or 22x24mm Fredette wrench by Moose will work both axles if you have non locking nuts on them Scotts and Dual Star also carry general tool kits with small ratchets and sockets screwdriver bits etc Where do I get one of those front disc protectors Acerbis used to make front disc and fork lower protectors for the KLR650 but unfortunately they ve been discontinued You can get protectors for the KLR600 and the DR350 Acerbis part number 51 98 to fit with some patient trimming How can I protect the rear brake disc Big Cee Engineering makes a sharkfin for the KLR650 Other companies make universal fit models Highway Gear return to top Replacement saddles There are several aftermarket saddles available to comfort your butt on a long ride The material is often firmer and the geometry ergonomics are different Some seats are wider making them more comfortable for long days on the road Note that this may reduce your mobility off road e Corbin There are three options for shape Normally the seat is dipped and dished If this doesn t leave enough padding the dip can be removed by being built up and the dish can be made flat file C
72. rear More street Galfer blue front FD091G1434 rear blue FD0751434 or black FD0751052 EBC sintered pads may work a little better than stock but can develop an occasional squeal If you re looking for something cheaper I ve had very good luck with Parts Unlimited TufStop pads TSRP 802 front TSRP 786 rear They re an organic pad that is very kind to rotors and grab much better than sintered pads They only last about 4 5 000 miles but at 23 pair that s a pretty good deal Dunlopad HH pads are available on the pricey end SDP313MX for the front and SDP310MX for the rear How can I get more braking power If you find the stock brakes aren t enough for you there are a few options First try some different pads as listed above Second replace the stock front brake line with a braided stainless steel unit Galfer and Russel make lines for the KLR Galfer front is p n FKO03D102 You can also get a braided line for the rear but the stock system is adequate This will give you noticeably better lever feel Finally EBC CycleBrakes and MAP make a larger front rotor with a relocating bracket for the caliper This is the most expensive but most effective option The CycleBrakes kit has a 320 mm rotor whereas the stock diameter is 260 mm An oversize Wave rotor is also available Do I have to pay 200 for a Kawi brake rotor EBC and Braking make aftermarket brake rotors for 90 120 Final Drive return to top How can I change the sprocke
73. s 520 x 106 links Incidentally the BMW F650 FAQ chain page is an excellent resouce How do I install the master link For a riveted master you will need a rivet tool which runs around 100 For a clip on link you should use a side plate press around 30 to seat the side plate The side plate on a clip on master link is designed to be a press fit and should only be used once It should only be pressed far enough to get the clip on and then should be backed out against the clip An alternative to the press is to alternate pins with a small C clamp and washers to allow the pin to come through How long will my chain last With regular maintenance you can get as much as 20 000 miles out of a chain What should I use to lube my chain Many people use fancy aftermarket lubes if you do make sure it s safe for O ring chains WD 40 has also been used to great success and it cleans the chain while it lubes it Finally the manual recommends 90W gear oil which is cheap and also works well although it will fling a lot of dirt on the bike What is the proper chain slack There should be 2 of play pushing up and down center to center midway between the sprockets The ultimate test is to compress the rear suspension as much as possible ideally engine output shaft swingarm pivot and rear axle in a straight line and see if the chain gets too tight You can use tiedown straps to pull down the rear or use your weight This can be done by fo
74. sure bypass for cold oil If you remove it your oil will not get filtered Occasionally mechanics accidentally discard this tube with the filter Make sure you have one If you re changing your own oil the tube only fits in the engine case one way What if I break strip out my footpeg bolts Some of the more aggressive riders have managed to break or pull out their footpeg bolts The simplest solution seems to be to convert the footpegs to M10 bolts drill out the footpeg bracket and drill and tap the mount The tap drill for M10x1 5 is 8 4mm or Q Do I need to have the valves checked at 500 miles Yes althought many dealers say otherwise Some bikes in fact don t need adjusting after 500 miles But some do so the clearances must be checked Checking the clearances is much simpler than actually adjusting them so you may be able to check them and then have the dealer change the shims At the least insist that the dealer give you a written record of the measured clearances After the first few valve checks i e around 9 000 miles you can probably set the valves at the maximum clearance and not check them for another 10 000 miles This will make the engine noisy but is acceptable Slappy valves are happy valves according to RM Dealers often adjust to the middle of the range to minimize engine noise Note also that hard starting and stalling when hot are symptoms of tight valves if you file C Documents and Settings J Christopher
75. sure spec 11 21 psi at 90 C 194 F and 4000 rpm The ultimate info on adding an oil pressure sensor can be found in post 61914 of the DSN_KLR archives In short the best way to add a pressure port is probably by stacking a second banjo fitting on one of the camshaft feeds Beware that adding a tap may add a failure point What size is the oil plug The oil plug thread is M12 x 1 50 Moose makes a magnetic drain plug p n M0103 and Dual Star makes a low profile one You can also knock some of the hex off of the Moose plug with a lathe or grinder Cutting down the drain plug is a good idea for off roading as it can stick out past the skid plate One Moose adopter reported having to run a thread die over the plug to get an easy fit into the drain hole A further option is Honda p n 92800 12000 How do I break in my new engine I don t really want to touch this one because it s nearly as ire provoking as oil choice Whatever you do you definitely want to vary load and RPM on the engine moreso in the first 50 100 miles but continue to do so for the first 500 miles A few good throttle whacks and then chops will build pressure to seat file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 11 of 41 the rings Also make sure the engine gets to full operating temperature Whether or not you want to observe the RPM limits suggested by KHI is up to you but I ve followed their guid
76. t it I also have a day job and might not be able to get back to you for a few days or weeks The FAQ is based on the A model through the 2007 model year Many aspects are similar to the C model but there is a list of differences here If there is something you would like to see or correct in the FAQ please contact me at ckrok at bigcee dot com and include the material if possible For an offline copy of the FAQ right click here to download a pdf Disclaimer This material is provided for reference only All information is accurate to the best of my knowledge but you are ultimately responsible for all mainenance of and modifications to your motorcycle Big Cee and or myself is not responsible for any damage that occurs as a result of use or misuse of this information Also note that any product or vendor opinions contained herin are culled from the general KLR owner population and are not the opinion of Big Cee Chris Krok In addition the listing of a company as a supplier does not imply endorsement People have had both good and bad experiences with nearly all of the vendors listed so you will basically have to try them and form your own opinion Caveat emptor Chris Krok General Information return to top Is a KLR right for me The KLR650 is a great all around bike It s relatively cheap is getting an increasing amount of aftermarket respect and easy to work on An experienced rider and some not so experienced ones can work it o
77. t radiator cap available Kawi Prestone Stant 49085 1066 RR 27 10227 Motrad TVS Gates T 13R 1 227B 31333 CST Balkamp 7513 703 4773 What is the KACR Kawasaki Automatic Compression Release This is a spring loaded weight on the end of the exhaust camshaft that partially opens one of the exhaust valves at low lt 600 rpm These are a known weak point on KLX bikes but there don t seem to be any many recorded failures of the KLR KACR Someone estimated that the pin on the unit gets beat 8x second in the operating RPM range which could be pretty hard on it People have totally removed the mechanism with no ill effects It may be a residual from the kickstarter option and not really needed with electric start Where can I get a kickstarter While the engine case still has a kickstarter hole 96 and later models can not use a kickstarter because of the redesigned clutch basket Earlier models can be fitted but factory kits have long since been discontinued Buying the parts individually is ludicrously expensive Best to keep an eye out for a kit on Ebay or such It looks like the parts from the 600 engine are the same Are there alternatives for the clutch Yes Rekluse Motor Sports makes a Z Start clutch for the KLR which is a combination centrifugal standard clutch The one downside so far is that you can t push start the bike without opening the engine back up but otherwise it appears to be solid A review is available at KLRWorld
78. t ratio The stock final drive ratio is 15 43 The easiest way to change the ratio is by replacing the countershaft front sprocket A 14T is great for tight off roading and a 16T for a lot of highway riding You can even make it through some hairy stuff with the 16T if you re good with the clutch For general use though the 15T is a good compromise There is also a 13T available although chain wear tends to increase as you decrease the sprocket size 16T is the largest that will fit If you have the engine open and can get the parts the 1st gear set input shaft 1st gear output shaft from a KLR600 can be installed giving you a lower first gear but keeping the upper gears intact Note that changing the countershaft sprocket rather than the rear will allow you to use the stock chain length For a writeup see here Are aftermarket rear sprockets available Yes but the factory Kawasaki part seems to be the most durable by far The price is also reasonable How doI mount the countershaft sprocket On 96 bikes the flat side of the OEM sprocket goes in towards the engine On earlier bikes the side with the flat surface for the retainer goes out With aftermarket sprockets the numbers are usually mounted outside but people have done it the other way Are countershaft sprockets interchangeable Here s the skinny file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 24 of
79. the plastic For chemicals you can try NU KOTE by Chemsearch acrylic floor wax lemon Pledge DOT 5 not 5 1 silicon brake fluid or S100 Engine Brite For a mechanical solution you can rub it down with 000 or 0000 steel wool and follow with a wool buffing wheel dry or use rubbing compounds Rubbing can be followed with 3M s Imperial Handglaze Can I repair my plastics file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 22 of 41 The KLR bodywork is made out of polypropylene a k a Tupperware for durability PP used to be impossible to bond but as it is being more widely used in the automotive industry adhesives were developed One of the best is 3M Scotch Weld Plastic Adhesive DP8005 Thanks Mike Can I get aftermarket plastics Companies don t make aftermarket parts for the KLR like they do for dirt bikes Acerbis front fenders for 1999 2002 KTMs will fit if you enlarge the holes laterally with a file You will also want to add fender washers to the mounting bolts as the holes are large to begin with and the stock washers will have minimal contact with the plastic Acerbis part numbers for the KTM fenders are 15830805 Black 15830884 KTM Orange 15830881 Silver Price is roughly 23 There are also aftermarket mini fairings with built in headlights that can be swapped for the stock fairing Can I convert my A model to a Tengai You can make it Tengai ish R
80. the rear is more suceptible to tire rotation than the front A big plus is that if you run tires with stiff sidewalls double locks will generally allow you to ride out on a flat This is especially handy on a tight trail Ideally double rimlocks would be mounted 180 degrees apart to balance each other but some people have had too much difficulty changing the rear tire with this configuration In that case the locks can be moved to 120 degrees apart but balance weight will be needed Another option is to drill the rim for sheet metal screws but you may run the risk of shearing off a screw head in rocks and then you could be um screwed How do I keep water out of my wheels You can try Honda tire valve stem seals 42714 KA3 710 You ll have to bore the valve stem hole out to 12mm These also allow the valve stem to flex and show if the tire has rotated on the rim Not sure if they ll work with rimlock bolts or if you d even want to use them in that application What are the correct tube sizes The standard tube sizes are 2 75 3 00 21 in the front and 4 00 5 10 17 in the rear Ultra heavy duty tubes are available for both the front and rear The Dual Star rear tube is an 18 but this works fine Arrowhead Motorsports carries a true 17 4mm tube for the rear Do I need to carry two spare tubes For lightweight packing a front tube will work in the rear tire for limited distances You should inflate it to the maximum tire pressure and ch
81. this you can 1 before starting the engine put the bike in gear pull in the clutch and rock the bike back and forth until the clutch breaks free 2 with the engine running in neutral with the clutch in blip the throttle a few times 3 start the bike rolling with your feet before putting the transmission in gear to minimize the lurch What s this diesel KLR I ve heard about Hayes Diversified Research and F1 Engineering of Hesperia CA converts KLR650 engines to diesel for the USMC With additional modifications the bike becomes the M1030M1 motorcycle They will be releasing civilian models shortly The first 100 bikes will be collectors items and will sell for 16k each with deliveries starting in 2008 Orders can be placed starting October 2005 and a deposit will be required and placed in escrow Read any good books lately e Bob Sanford Riding the Dirt Written in 1972 this classic covers the basics of dirt riding While the equipment may have changed the basics have not In fact it s amazing how little some things have changed e Of course there s Dual Sport News links section probably the only magazine dedicated to adventure touring Especially good is The Gino Years on CD ROM which contains all of the articles from the days when it was a KLR specific magazine e Dirt Rider Magazine But Chris isn t that all just play bikes and fashionable gear Well yes there s that But Dirt Rider also has a regular feature c
82. ulbs have a tail light rating of 5 000 hours There is also a halogen version the H1157 but this can melt the taillight housing if the brakes are on for a long time i e stop go traffic An excellent alternative is the LED board sold by Dual Star made by someone else This is a circuit board that fills much of the lens with LEDs and has the option to flash the light a few times when the brakes are applied This is a much file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 21 of 41 better alternative to the little LED bulbs that attempt to directly replace the 1157 these aren t usually too bright How do I test my CDI unit Despite the extensive resistance table given in the manual the best way to test a CDI unit is to swap it with a known good one Replacements are expensive but a cheaper programmable unit is supposedly available Can I replace the glass fuses with modern ATO blade types There are three options e Cut the wires to the fuse box under the seat and run extensions to the side stand switch area Splice in weatherproof ATO fuse holders and install the appropriate fuses Also do this for the fan fuse near the coolant tank e Dualsportrider links makes a plug and play kit that relocates the under seat fuses per above and converts them to ATO e An alternative is to put ATO sockets under the seat but instead of fuses use auto resetting circuit br
83. ven a relatively new battery can be bad if it was not properly charged before use or has sat for a while without charging Sometimes this can appear to be a short i e you turn the key on and the headlight comes on but everything dies when you hit the starter The voltage may slowly creep back up after you remove the load Auto parts stores may be able to load test your battery and see if it will hold a charge Will my bike explode if I jump start it from a car NO This is a myth perpetuated by people who don t understand electricity However the car engine should be OFF when jumping the bike starting a motorcycle won t put much of a dent in a car battery You do need to be careful for the following reasons e The car engine should not be running when jump starting the bike because the two charging systems are quite different A motorcycle regulator in a system with a permanent magnet charging system like the KLR works by dissipating excess charging power as heat An alternator system in comparison controls the strength of the magnetic field The automotive alternator is also much more powerful than the motorcycle system so it can overwhelm the battery e If your bike has a dead battery you had better be damned sure you don t have a short somewhere before jump starting it from a car A small short circuit may not get out of hand when connected to a motorcycle battery i e the charge voltage will drop more quickly but a car battery
84. ver black diamond single track it can carve through the twisties and roll out on the highway However because it can do all of these things it doesn t do any of them particularly well It can be a lot of work to ride offroad especially in sand or deep gravel It doesn t have the best wind protection and the light weight and upright riding position lets it get blown around by wind on the highway If you want something more dirt oriented you might want an XR DR or KLX if you want something for the highway you may want a standard or sport tourer But if you want to ride a thousand or more miles go offroading and ride home the KLR is a great choice The KLR s capabilities can be tilted towards dirt file C Documents and Settings J Christopher Krok My Documents BigCee website klr 10 27 2009 KLR650 FAQ Page 3 of 41 or street through changes in tires gear ratio suspension and other areas How do the models differ The A model is the basis for the FAQ and is further described herein It was primarily available in the United States and Canada through the 2007 model year The B model was only available in the US for the 1990 model year but was available in the rest of the world for a number of years thereafter The C model is sold outside of the US and Canada although the latter country has seen limited numbers of them All three versions share the same engine The B model is almost identical to the A model except for the obvious d
85. veral brands of paper filters are available and are cheaper than Kawi filters Fram CH6070 EMGO 10 30000 K amp N KN 123 Wix 24951 NAPA 4951 I believe that both the Wix and Napa filters are made by Wix The Wix Napa and Fram filters come with new O rings and the others do not If you are ordering from Dennis Kirk the replacement O ring is p n 30 143 There is also a lifetime stainless steel filter available which you clean at each oil change It s a bit pricey and there is still some debate over which type of filter is better The SS filter has a consistent filtration level the paper filters vary from better to worse than the SS Some people believe that paper filters shed fibers that wind up clogging the oil strainer screen However it is more likely that this is clutch or gasket material After 25k mi on my bike there was no fibrous material in the strainer Strainer screen What strainer screen The oil strainer screen prevents large chunks of stuff from getting into the oil pump It is a fingertip shaped screen about 3 4 in diameter with a black rubber gasket at its base To get to the screen you must remove the right side cover clutch cover The screen is at the bottom pointing into the engine People usually find a few chunks of gasket sealer material stuck to the screen Can I install an oil pressure gage or warning light Because the crank rides on roller bearings rather than hydraulic ones the KLR has a low pres

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