The chrome links line up only once in every 9 revolutions of the engine if memory serves me well. Just keep rotating the crank around until they all line up with those dots.
Aha, I gave up removed the old and installed the new! And now I quoted myself again ....and its BAD (got worried so ripped it apart now instead of tomorrow!)!!!!!! <a href="http://www.flickr.com/photos/dirtyadv/6639395233/" title="Not looking good by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7016/6639395233_7fc3b18ddc.jpg" width="500" height="375" alt="Not looking good"></a> VERY BAD: <a href="http://www.flickr.com/photos/dirtyadv/6639397327/" title="In fact very BAD by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7009/6639397327_b1e7a05b75.jpg" width="500" height="375" alt="In fact very BAD"></a> Started filtering the oil I drained, said only for decorative use on the pottery: <a href="http://www.flickr.com/photos/dirtyadv/6639401165/" title="Filtering the oil (said only for decoration in the pot) by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7164/6639401165_ebc08bbbdd.jpg" width="500" height="375" alt="Filtering the oil (said only for decoration in the pot)"></a> WTF??????? What is this?????? Where could it have come from??? Almost clogged the filter screen to the point it looks like it was on its way to collapse, its like some kind of silicone, did not come from the failed bearing! <a href="http://www.flickr.com/photos/dirtyadv/6639409237/" title="WHAT IS THIS?? by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7152/6639409237_4d3f858534.jpg" width="375" height="500" alt="WHAT IS THIS??"></a> Hmm rollers! <a href="http://www.flickr.com/photos/dirtyadv/6639421801/" title="Hmm rollers by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7031/6639421801_c5c7a4e3d0.jpg" width="500" height="375" alt="Hmm rollers"></a> Still can't fully account for all the pieces from the bearing, need to get hold of a magnet to try to search the bottom of the engine tomorrow, didn't feel like ripping it all apart! <a href="http://www.flickr.com/photos/dirtyadv/6639424081/" title="Still miss a few by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7023/6639424081_2e0583b3ff.jpg" width="500" height="375" alt="Still miss a few"></a> Can see the $bills flying away from me!!!!! ARRRRRGH!!!!!! So questions this time where did the brown gunk come from???? /Johan
None that I can see. On Generation 1 KLR650's (pre-2008 model year), the battery charging and ignition circuits are completely separate; thus, IMHO, absence of a battery is of no consequence in running the engines on these machines. Link to Generation 1 KLR650 wiring diagram, FYI: http://www.wiringdiagrams21.com/wp-content/uploads/2008/07/Kawasaki-KLR650-color-wiring-diagram.gif
The brown gunk is gasket sealer from the engine assembly at the factory. Some oil screens come out nearly clogged with the stuff, like yours, and some come out with almost none at all. That's why it's a good idea to check and clean that item.
I just made a call on one (2011). Should I buy it I want to make a slow trip to Montreal this summer.
Found more while searching for rollers with a magnet (can be seen down in the hole): <a href="http://www.flickr.com/photos/dirtyadv/6644438435/" title="Hmm can see some brown gunk by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7024/6644438435_8791a41987.jpg" width="500" height="375" alt="Hmm can see some brown gunk"></a> Opened the filter to see quite a bit of metal shavings, expected it, would almost have hoped for more, can only count 17 out of the 19 rollers (1 is missing in the picture). Means I probably have some left in there somewhere, have installed a magnetic drain plug and plan to fill it with the cheapest motorcycle oil I can find start it up a little and do a very quick oil change after that: <a href="http://www.flickr.com/photos/dirtyadv/6644430745/" title="Some metal shavings there by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7171/6644430745_be1b638251.jpg" width="500" height="375" alt="Some metal shavings there"></a> Also put a cap on the tank for the decalifornication, hope this is enough: <a href="http://www.flickr.com/photos/dirtyadv/6644488049/" title="Plugging the extra tank outlet by Dirty Adventurers, on Flickr"><img src="http://farm8.staticflickr.com/7027/6644488049_c9e7cbbca8.jpg" width="500" height="375" alt="Plugging the extra tank outlet"></a> Hope the parts ordered arrive in time so I can get it back together before heading back home to Sweden! /Johan
My buddies '06 is making god awful noises. They started all of a sudden. One day it was fine, the next, it sounds like hammers in a blender. It has 8K on it. Sounds just like this: <iframe src="http://www.youtube.com/embed/KJLXUCI1z30" allowfullscreen="" width="420" frameborder="0" height="315"></iframe> So far we've checked the doo-hickey, valves, KACR, clutch basket, piston, rings, wrist pin, and small end. All were in spec, and showed little sign of wear. Crank does not seem "loose". I'm thinking it might be the mains, but I'm wondering if you guys could think of anything else it might be, before I split the cases. Any ideas? Hunter
It seems you have checked most of the "mechanical" parts. Sounds a bit like a dead, or partial spark cylinder on the video where as it's not firing completely and "slapping" in the cylinder. Have you checked the coil and related systems? Just a thought.
What is your idle rpm speed set at? If too low they do sound rough. But as soon as you pick up the revs it sounds normal from where I am sitting.....? If you allow it to idle below 1100rpm then it sounds like it's slapping the piston and having difficulty firing so to speak. As you rev it even slowly it sounded fine. It was hard to hear it completely over your loud pipe...? Try and refilm it with the camera further away from the exhaust. How does it sound when it's trying to start? Tape it as it starts and idles at the correct 1100 or 1200 rpms then slowly up to 3000, no need to go higher as it sounded fine once reved....hope this helps
There are less expensive foot pegs listed on fleabay that list fitting the Kawasaki KLR650 1987-2005. My KLR is 2006. Is there a difference between 2005 & 2006 that would cause these pegs to NOT fit? Thanks!
No difference in pegs 87-07 as far as I know. If they are the 19.99 ebay china specials I have them and like them. They've held up fine (including a few airborne "flying pig" maneuvers) with no problems other than some light surface rust on the cleats where my boots have worn the paint away. Mine sits outside 24/7 so rust is inevitable.
Well worth it. I've got many thousands of hard miles on mine. Mine didn't come with springs though...
I recall a post somewhere about a company that will install stiffer springs on stock rear KLR shocks but I can't remember the name of the company. The stock shocks are optimized for a 160 pound rider and I tip the scales at about 250 before breakfast!
Hi guys, I'm more than likely going to purchase a 2008 KLR650 to use as a daily commuter. The bike has had same owner since new and has had oil changes every 6000km apparently. The odometer reads 61000km and the bike looks to be in very good condition. 1/ What should i be looking out for as far as wear goes. :eek1 2/ How much / how hard is it to do an overhaul of these motors? 3/ How much would an overhaul be? I don't know anything at all about these bikes other than the fact that they are like a DR650 for the road!!!! I would appreciate your knowledge, comments and assistance. Regards, Rob
That is top gun. They make a bunch of different springs for the klr. Sent from my ARCHOS 80G9 using Tapatalk
The 08 up burn some oil at high speeds. Meaning high rpm. The klr will go anywhere the Dr will. Anywhere. Plus its way more comfortable, has alot more range and 100% more wind protection. The only thing you NEED to do is change the doo spring. Or the complete doo hickey. The motor is dmn near indestructable once that is done. Unless you flog the crap out of it at which point nothing lasts. I have 7000 on my 08. I'm upgrading suspension to take the weight of the extra gear and wife on the back. I'm using the new progressive shock wth rap, progressive springs and ricors up front with motowizard preload adjusters to dial it all in. The motor is getting the 705 with hotcams etc finally too. A little extra ooomph for the big hills here in east coast of Canada. I would not trade the klr for anything beside the ktm 990 r, but after all the mods I have done, I'm still only 1/2 the cost of a new ktm. If that. Sent from my ARCHOS 80G9 using Tapatalk
