KLR 650 Modifications

Discussion in 'Thumpers' started by VascoMerlin, Aug 24, 2006.

  1. Grinnin

    Grinnin Forever N00b

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    Dec 10, 2005
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    2,984
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    If you're asking me, you'll have to wait. A full tank at the end of break-in (no constant throttle) was 51 mpg with the side cases just 1" narrower than the OEM handlebars. I'll have a normal-throttle fill-up today. The bike suffers from a very enthusiastic right wrist.

    EDIT:
    [​IMG]
  2. Jettn Jim

    Jettn Jim This is Liv'n!!!

    Joined:
    Mar 28, 2010
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    1,837
    Location:
    NE PA Some... PNW Some... On HIGH ADVENTURE Most!
    Sorry guy's been a bit busy getting everything home from up Nord....
    I'll answer the gas question first.... if ya open up the airbox and fatten her up she'll drink a good bit. But with 4-1" holes, snorkle gone etc... and pretty lean/mean jetting I get near 40MPG when I can keep her under 5,000rpm on sustained loooonng days, without head winds and such. I can get her down into the upper 20's if I run her into the mid 80's all day bucking headwinds noo prob.

    So your results will vary...

    As for all the engines...:lol3 not sure I wanted to use the smiley face but I might as well laugh, otherwise I'd scowl or cry and I don't like to do that EVER!
    The way that I ride cross country all the time.... just happens to NOT agree with a thumper! :deal
    Guy's ride em around the world all the time etc.. etc... BUT they don't ride WFO all day every day which is pretty much how I ride. I believe thee ol' thumper just beats itself to death over the duration of 500-1,000mi days over and over and over. Desiree' has logged more than 62,000mi in two yrs and her average speed is probably higher than most folks top speed on most days.

    I believe I'm back to the realization that if I'm gonna keep doing these long slogs.... I'm gonna need a twin. :cry

    If I could stay within the PNW (but I have to cross the US to get there twice a year) doing shorter rides and then the forest roads and trails she'd live. Of course I'd have to sloooow down a bit on the slab.

    So it basically comes down to me and my hyperactive nature. This bike isn't hyperactive but I ride her like she is.
    I've got a fun thing planned at the end of my current Ride Report (HighAdventureTour2012: From Insanity and Beyond) which will change things drastically for Me, Desiree' and someone else.

    Stay tuned to it if ya wanna find out.............:pynd
  3. Aprilia

    Aprilia Been here awhile

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    Expect same mileage as you would from a stock engine. Mileage is based on right wrist...expect mid 40's to low 50's.
  4. PacificPT

    PacificPT Been here awhile

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    Aug 23, 2006
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    Jettn Jim,

    Thanks for replying about the 3 engines. Makes sense running long distance high speed on a thumper you would burn through them more than the commute and trail riding. What twins have you thought about?
  5. FJracer

    FJracer Adventurer

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    Jul 5, 2008
    Oddometer:
    77
    Location:
    Natchez Trace Area, Tenn
    Lost All Power going up a hill after downshifting to 4th before the curve and hill. No gears will pull. Did see Neutral Light when down shifting after stopped. Is this the dreaded Doo-Hickey Sydrome? Bike is stock with 23,000 miles. Heard absolutely no grinding or distress coming from clutch/tranny. Just in permanent Neutral.
  6. sandalscout

    sandalscout blah blah blah

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    May 31, 2010
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    Is the bike actually running?

    Doesn't sound like the doo to me, if that goes, it usually takes out the top end and nothing runs.
  7. FJracer

    FJracer Adventurer

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    Motor humming along smooth. Just no gear to find in tranny. I'm thinking maybe a shift rod, 'cause I'm not sure I got a solid downshift into 4th. Seems like it disengaged as I powered up a steep hill. I rolled to a stop at the top and tried to find a gear. None.
  8. sandalscout

    sandalscout blah blah blah

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    Yeah, definitely not the 'doo then. I know next to nothing about motorcycle transmissions, any chance it's clutch related?
  9. Yokomo

    Yokomo Gorilla Adventurer

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    Probably the shift fork if I were to guess.
  10. Dolly Sod

    Dolly Sod Red Clay Halo

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    Richmond, Va
    Stripped your counter shaft splines.
  11. FJracer

    FJracer Adventurer

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    Well that doesn't sound good at all! I thought these Bikes were suppose to be "Bulletproof"!!!
  12. Dolly Sod

    Dolly Sod Red Clay Halo

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    There is no such thing.

    I know in the 10,000 miles that I had my KLR the counter shaft splines showed a decent amount of wear. Some of the Single 650 GS's have stripped their countershaft splines and place the blame on aftermarket sprockets that are too hard and wear the shaft splines down instead of wearing the sprocket splines.

    I'm just guessing though, but it's pretty easy to determine if the counter shaft is turning, just pull that sprocket cover off.
  13. Yokomo

    Yokomo Gorilla Adventurer

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    "Bulletproof" cracks me up. Most everyone says every bike they own is "pretty much bulletproof".
  14. Aprilia

    Aprilia Been here awhile

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    Sounds like the shift pawl spring. I've replaced two of them this year in my shop for other riders. No big deal...removed right side cover to verify. You'll need outer case and waterpump gasket as well. Good time to clean the oil screen too.

    [​IMG]

    Just in case did you get down on your hands and knee's and carefully look over your shift lever and its attachment point to the shift lever. I've seen quite a few factory lever's crack at the weld and not allow enough leverage to turn the shaft.
  15. FJracer

    FJracer Adventurer

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    In the daylight, it turns out, I broke the drive chain. Problem solved..........................kinda! I guess this engine IS "Bulletproof"!!! So powerful it can break a perfectly good chain at full power up a steep hill.
  16. CA Stu

    CA Stu Steer with your face! Super Moderator

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    :lol3

    Change your chain out sooner next time!

    At 23000 miles, I'd be thinking about chain number 3!

    To be honest, I broke a chain on my KLR once, too. 13,000 miles on the chain and a nice big rock between it and the rear sprocket and ka-pow!
  17. Yokomo

    Yokomo Gorilla Adventurer

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    23k on stock chain and sprockets? Yes you need to change sooner. Get new chain and sprockets.
  18. Aprilia

    Aprilia Been here awhile

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    Good grief...really? Thats 5 min of my posting life I'll never get back. :evil

    On a serious note...engine that is 'bullet proof' is a direct correlation to the owners ability to properly maintain much less just keep oil in it.
  19. FJracer

    FJracer Adventurer

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    Thanks for the advice BUT I don't remember telling anyone that was the original chain. In fact it was reasonably new EK as well as the sprockets. I bought the Bike in Aug. with 22K on it. Previous owner stated chain fairly new. And that was verified when the front sprocket was swapped out. The 15T I put back on was the original and it looked good to me ........... at the time. In retrospect, I may replace that one..................or both. I recovered the Chain just a moment ago when I came back for Dr. appointment. One link just broke.
  20. CA Stu

    CA Stu Steer with your face! Super Moderator

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    Master link?