[Hessian42]

The bike 99 KLR 650 6,500 miles



The list.

-Doo hickey
-Fork oil change
-Check valves
-adj. suspension w/ luggage
-Lube wheel bearings
-Lube stem bearings
-Lube swingarm bearings
-Bypass kickstand & clutch sensors
-Check spokes
-Check spark plug burn/ adj. carb if needed
-Radiator flush
-Install new brake pads/bleed brakes
-Oil/ mount UNI filter
-Mount 16T front sprocket/ adj. chain
-Oil/filter change
-Clean oil screen
-Footprint side stand
-Fab pannier rack
-Fab water/gas cradles
-Fab highway pegs
-Fab rear rack
-Wire 12v outlet
-Change to mini fuses
-Mod windscreen
-Install tool tube
-Install bar risers
-Install bars
-Install hand guards
-Install new grips
-Die-electric grease plugs


Done (5,400k miles)


-Flushed/bled front/ rear brakes
-Adjusted rear brake pedal
-Cleaned, adjusted and lubed chain
-Cleaned air filter, airbox, de-snorkled
-Lubed throttle cables
-Cleaned/rebuilt/adjusted/modified carb
-Yamaha raptor 660 petcock
-Topped off antifreeze
-Oil/filter change
-Adjusted/lubed clutch cable
-Adjusted shift lever
-NGK iridium plug
-Torqued/red loctite all critical bolts

Day 1












Initial impression is highly optimistic. Looks like no one has laid eyes under this ladies skirt since back in Japan. Both axles came off without the aid of a big hammer and even had a gentle dab of grease applied to em. The stem bearings and races look flawless and were well greased. Her wheel bearings look new and were packed full of factory grease, not to mention smoooth. As for the infamous doohickey it appears intact and in place. Day 2 around the corner.

Day 2

Some progress is better than no progress at least so it goes. Another day of dis assembly and again i'm surprised at how easily everything is coming apart. Nothing has fought me and other than a dead blow i've used nothing but what's in my kit. Bearings are as shiny as they should be and nothing is corroded or worn. Picked up some "green grease" waterproof junk at the parts store and lubed every orifice within sight. My plug was on the lean side of brown so i threw another shim on the needle. Also went ahead and pulled the right cover off and wasn't surprised by all the silicone on the oil screen, seems the norm. Picked up some metal today so next time sparks will fly.

Day 3


















Another night and there are more parts on the bike than the floor. The infamous Doo has been taken care off. Mine was intact and so was the spring with plenty of tension left as well. I know i'll sleep better having the new one in along with the torsion spring. Real shitty design on kawis part! While on that side of the bike i figured i'd also beef the welds on the shift lever i hear so many raving about. Figured the hundred bucks on a fancy after market would be better spent on tires. Threw the swinger and front end on and made sure i green greased everything to hell. Would have changed the fork oil but noticed i bought the wrong weight so bars stayed off. Threw a 16 tooth sprocket on there and as much as i wanted a new chain just couldn't bring my self to throw out a EK with less than 2k on it. Same with the dunlops. She did need new brake pads all around very badly. Didn't get to fab today but tomorrow is another day.

Day 4

Sleeping in the shop, work, eat repeat. Procrastinator's revenge. A lot of work going on and still not done. Since the departure date has come and gone a few more days won't break the bank. Churchills and a final guiness await before i leave this hole behind for good.


Day 267...

With a final 27 hour straight push the steed is done, anchors are packed and at first light freedom is within grasp. North leads the way out, GA, TN, NC, VA here we come.

See ya'll on the road!