KLR650 Only Thread......

Discussion in 'Thumpers' started by willys, Nov 19, 2011.

  1. thechief86

    thechief86 Been here awhile

    Joined:
    Sep 5, 2015
    Oddometer:
    560
    Location:
    White House, TN
    Thanks fellas. The doohickey in the 89 case is an Eagle Mike unit, which was why I considered swapping it over.
    Good to know that the 89 cams are a little better, and that I'll need the 89 cam cover with that head.
  2. Aprilia

    Aprilia Long timer

    Joined:
    Sep 15, 2008
    Oddometer:
    1,452
    Location:
    Phoenix, AZ
    EM Doo kit will swap right over. Yeah, Kawi changed the profile beginning in 08. I would assume for emissions reasons. Thus the advancing of the exhaust cam by one tooth on Gen2 is popular. Gains a bit back by doing so.
  3. PapaWolf

    PapaWolf When the going gets weird, the weird turn pro.

    Joined:
    Dec 29, 2014
    Oddometer:
    263
    Location:
    Portland, OR
    Well after letting the project sit for awhile, I went back out to the garage. I pulled out the multimeter and it turns out it is the power (positive) that I’m missing to the right rear signal. The ground is good. There is no power at either the bulb socket or the connector.

    So, how would one go about figuring out where exactly in the rest of the wiring harness this short or open might be?

    I run an audio video production company, and am pretty good at troubleshooting A/V stuff. You would think I would be better at troubleshooting electrical!
  4. GreatWhiteNorth

    GreatWhiteNorth Long timer

    Joined:
    Dec 2, 2009
    Oddometer:
    4,369
    Location:
    Winterpeg - site of flatness beyond belief
    I've unwrapped a couple of Gen 1 wire harnesses to troubleshoot 'em (no neutral light). I've found that sometimes you can't visually see anything wrong with them, but they've a break somewhere hidden under insulation. A new ('07) Gen 1 harness is less than $100, a bargain, and a cheap way to freshen up an older bike.

    The electrical troubleshooting I was taught, recommended to break the circuit in half, and start metering for continuity from there.
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  5. jjxtrider

    jjxtrider questionable

    Joined:
    Aug 17, 2013
    Oddometer:
    3,600
    Location:
    Halfway to hell (WI.)
    I start at the circuit source of power and make sure there is power going in , then find the first connection and check for power/continuity there , then on to the next ect. till you find the connector that it doesn't make it . You'll then know it's in just before that point . You can either unravel the harness or simply run a new wire(s) to bypass it then. If the harness is obviously bad in a bunch of spots or in rough condition a new harness may be ideal.



    .
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  6. tac650

    tac650 Nomad

    Joined:
    Oct 9, 2004
    Oddometer:
    712
    Location:
    Salem, OR
    I would check at the turn signal switch switch. I believe Gray one direction and Green the other direction. From there each wire splits and one goes froward and one goes rear. I'm not sure where the split is it may be near the front turn signals. Maybe at the connector for each front turn signal?
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  7. PapaWolf

    PapaWolf When the going gets weird, the weird turn pro.

    Joined:
    Dec 29, 2014
    Oddometer:
    263
    Location:
    Portland, OR
    Well, I started running through the harness with a friend, starting with points that looked like they were bulging (potential old splice or connection) or kinked/bound. After opening the harness in a few places, we found the problem!

    The harness runs under where the gas tank bolts thread into, and at it looks like non-stock (too long) bolts were used at some point. They were long enough to punch through the wiring harness and start marring the airbox plastic! So, there is a nice hole through the harness there, and thankfully it only severed the power wire for right rear signal.

    So, a relatively easy fix, thank god!

    Thanks to everyone for their thoughts and help.

  8. DSquared

    DSquared Thumpin' Along

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    Mar 13, 2015
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    Location:
    Burlington, WI
  9. John Fry

    John Fry Adventurer

    Joined:
    Jan 4, 2009
    Oddometer:
    17
    Can anyone confirm if the rear footpeg brackets off a 2012 will fit on a 2008?
    Bike Bandit shows different part numbers.
  10. Bell driver

    Bell driver Long timer

    Joined:
    Apr 21, 2010
    Oddometer:
    1,026
    Location:
    Germany, Nordish By Nature.
    Yes, they fit. Part# are different because the 2008 are silver, 2012 are black.
    thechief86 and John Fry like this.
  11. John Fry

    John Fry Adventurer

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    Jan 4, 2009
    Oddometer:
    17
    That's what I thought. Thanks
  12. k5mitch

    k5mitch Been here awhile

    Joined:
    Jul 11, 2013
    Oddometer:
    445
    Location:
    Toano, VA
    I'll put my questions up front here, and if you want to read some fluff, just keep reading :)

    The gas tank has no vent hose attached. What size hose should I scrounge up?

    Is there a way to inspect the doo and spring without pulling the case cover off?

    Do any of you use a jack with the KLR in your garage, if so which (and does it get both wheels off the ground)? My previous bikes all had center stands, and it's my understanding that center stands on the KLR have the potential to muck things up a bit if you bang them just right offroad. I've been using a carefully calibrated 2x4 to prop up the swingarm for doing chain and sprocket maintenance. Lifting the bike up level a bit sure would be a lot more comfortable...


    I bought a 2009 with 28k miles about 1 month ago, the PO did some 'work' to it.

    Since then I've:
    • Replaced the ragged dirty OEM air filter with a uni filter
    • Replaced the FMF Powercore exhaust with the stock boat anchor (I like quiet bikes for some weird reason)
    • Gone through the carb ("22 cent mod" they said) - yep, slide was drilled, different needle installed, DJ150 jet installed, idle mix was over 3 turns out -- :yikes: -- The spark plug was fouled and the exhaust smelled terribly rich, so I installed a DJ136 jet, set the DJ needle at the 2nd groove, and set the idle mix for about 2.5 turns
    • Replaced the fouled iridium spark plug with a properly gapped DPR8EA9
    • Inspected the cam journals - Looked great!
    • Checked the valve clearance ("Valves checked recently" they said) - My smallest feeler is a 0.005" and I could only fit that on the Right Intake. Pulled all the shims and they were all what must have been the original 270 shims. Ended up with Exh: 260/0.008 260/0.009 Int: 260/0.008 265/0.007 by the time it was all said and done
    • Replaced the 16T sprocket with a 15T, installed a new chain, and EM prevailing torque nut.
    The motor runs great now, and the exhaust no longer smells rich. If it weren't so much of a PITA to pull the spark plug, I'd check it to see how the fueling mix is. I think I'll probably do that when I pull the fairings off to replace a bent fairing stay and coolant reservoir shroud. As great as the 16T and 140 K60 rear was at 70 MPH+, it doesn't fit the kind of riding I do. 15T with the 140 rear tire works pretty well I think (~2% increase in circumference IIRC). If I went to a 130 tire I might be tempted to try a 15/42 sprocket combo with it

    Having come from a Honda ST1300, I'm loving the simplicity of working on this bike.
  13. HardWorkingDog

    HardWorkingDog Harvey Mushman

    Joined:
    Aug 20, 2009
    Oddometer:
    2,657
    Location:
    Walnut Crick, Cal.
    Yes, I use the Craftsman "Pro" MC jack, found it on sale, very happy with it. Keeps both wheels off the ground at a nice workable height.

    [​IMG]
  14. Pollack

    Pollack Adventurer

    Joined:
    May 31, 2014
    Oddometer:
    637
    You'll have to at least take off the outer cover to have a look. If it were mine I certainly would, at 8K miles mine failed.

    Best regards,
  15. Pollack

    Pollack Adventurer

    Joined:
    May 31, 2014
    Oddometer:
    637
    I picked up the HF version for $75 a couple years ago and it has worked without any issues.

    Best regards,
  16. EnduroRdr

    EnduroRdr Woods Racer & D/S Rider

    Joined:
    Feb 15, 2008
    Oddometer:
    2,301
    Location:
    Formerly South MS, LR-Ar, Houston-Tx, now BR-La
    Same here: HF jack works fine.
    I also agree with Pollack about inspecting your doo.
    If PO never really did valves then he probably never adjusted doo. Hopefully your spring kept its tension.

    But I'd probably convert to EM torsion spring and doo lever anyway. Sounds like you are pretty mechanical savvy, should be a easy job for you. Parts are pretty cheap, so try to find someone to barrow the doo tools from.


    Sent from my iPhone using Tapatalk
  17. Pollack

    Pollack Adventurer

    Joined:
    May 31, 2014
    Oddometer:
    637
    I have only read extremely complimentary reviews & comments about the ST line. Why did Honda quit manufacturing the ST? Why is it still on there website years later?

    Best regards,
  18. k5mitch

    k5mitch Been here awhile

    Joined:
    Jul 11, 2013
    Oddometer:
    445
    Location:
    Toano, VA
    They never updated the bike. With the exception of standard ABS and adjustable windscreen, they are the same from 2004-2012.

    There are a ton of 2012 leftovers still on dealer floors. The 3rd gen FJR really did them in.

    Now we have the CTX1300... don't ask me why...

    Sent from my Nexus 7 using Tapatalk
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  19. k5mitch

    k5mitch Been here awhile

    Joined:
    Jul 11, 2013
    Oddometer:
    445
    Location:
    Toano, VA
    Thanks for the input on the lift and doo. I'll put the doo on my list of things to inspect at the next oil change.

    Sent from my Nexus 7 using Tapatalk
  20. Grinnin

    Grinnin Forever N00b

    Joined:
    Dec 10, 2005
    Oddometer:
    4,387
    Location:
    Maine
    I have had the HF lift for a few years and it's always worked fine for bikes and half a tractor. For the curved bash plate I have on the KLR, I use a couple wood 1x1s to keep it from rocking side to side.

    A neighbor got a nearly identical lift for an almost identical price from Sears during one of their sales.