KLR650 Only Thread......

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

  1. firewatermetal

    firewatermetal Adventurer

    Joined:
    Oct 12, 2009
    Oddometer:
    32
    Location:
    Arkansas
    Yesterday the subframe bolts broke on my KLR. I only noticed it when the back-end was sitting on the tire all the sudden while I was riding.

    They seem to have been broken for a while and my mistake was not checking them earlier. The good news is that I was only 1 mile from home.

    Looks like I'm going to have to attempt to use an easy-out to remove the broken bits and then attempt the upgrade to the bolt.

    When the rear was dangling off the back this put tension on the battery cable and other wiring; this tension broke the neg. battery post. Looks like I will be getting a new battery out of the deal, unless I can figure a way to salvage the broken post.
  2. tommu56

    tommu56 Long timer

    Joined:
    Sep 11, 2011
    Oddometer:
    1,422
    Location:
    limerick pa / waterville pa
    Look at eagle mikes drill through kit might save you some hassle.

    http://www.eaglemike.com/Drill-through-subframe-upgrade-kit-DTSUK.htm

    [​IMG]

    tom
  3. A1pheus

    A1pheus Electronics Guru

    Joined:
    Jan 6, 2013
    Oddometer:
    2
    Location:
    Warrenton,VA
    Cant go wrong with Eagle Mikes Drill Through. I installed it on a project I'm working on.

    Its long because this is the SW Motec Crash Bar kit...

    [​IMG][/IMG]
  4. PWRCRZR

    PWRCRZR Grumpy Old Bastard

    Joined:
    May 10, 2008
    Oddometer:
    7,699
    Location:
    Mid-Coast Maine
    I lost both my upper bolts last spring on the way home from a 4 day camping trip....I ended up getting a ride home from the wife :deal

    I chose the drill through method for repair and while it was a little difficult drilling through grade 10 bolts it was not impossible. And probably much easier than trying to easy out the broken bolt remnants.

    [​IMG]
  5. kdzidoc

    kdzidoc Adventurer

    Joined:
    Aug 1, 2012
    Oddometer:
    27
    Location:
    cookeville, TN


    Good call. The Givi looks way too big now that I see it on a bike. The bike cable lock sounds better.
  6. IDRIDR

    IDRIDR Take me to the River

    Joined:
    Jun 16, 2010
    Oddometer:
    1,575
    Location:
    Boise, Idaho
    I just replaced the 10.x upper subframe bolts, one lower 10.x, and one lower stock grade, with 12.9. The local KLRistas said that 12.9, properly torqued, will not break unless I'm extreme on load and trail. Do ya'll know of 12.9 (non drill through) upper bolts shearing?


    thanks.
  7. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,283
    Location:
    Tulsa... it's OK
    I can't recall if it was this thread where we recently had a discussion on the non-stock choke options... :dunno

    Anyhow, I got around to installing the KLX plunger choke today. Two trips to the carwash still couldn't get all the dirt off my bike from the New Year's Day Hangover Ride, so I made due.

    With the IMS tank, this little choke is nearly impossible to reach, so before I installed, I drilled 2 holes in the knob and threaded some wire through it so I had something easier to grasp. The choke clicks into the full-on position and with a little nudge snaps back to the off position, which I like.

    The wire I added allows it to be situated right above the petcock and I can grab it without having to search around. I don't have a review on real-world usage yet, but other inmates have noted success with this part swap...

    Mediocre cell pics:
    [​IMG]
    [​IMG]
    [​IMG]
  8. Hessian42

    Hessian42 Been here awhile

    Joined:
    Aug 12, 2012
    Oddometer:
    170
    Location:
    Dirty South
    Just throwing this out there............

    I'm currently 8,000 miles into my MIAMI to PATAGONIA trip and currently crashing in L.A with a fellow adver. I'm working to save up a few bucks to both prep the bike better for the southern portion of the trip and for much needed extra cash for the long road south. I'm on a tight ass budget and looking to upgrade a few key things on my KLR and was hoping maybe fellow advers might have stuff laying around i need and they'd let go off on the cheap.

    Looking for the following

    aluminum or steel bash guard any shape or make.
    heavier fork springs (250-300lbs load)
    radiator crash bar
    fork brace
    rear disc shark fin
    heated grips
    used water proof gps any kind as long as it works

    I have a fedex account and can take care of shipping as well as paypal.

    tks all!
  9. ParaMud

    ParaMud Been here awhile

    Joined:
    Jun 8, 2008
    Oddometer:
    631
    Location:
    Orange, CA
    Did a valve check on my 2 KLRs. I think it was the first one for both, maybe the 2nd for one of them. Out of both, only 1 exhaust valve was to tight. Still going to change them all out to the looser spec.
  10. BBGS

    BBGS East Coaster

    Joined:
    Nov 9, 2003
    Oddometer:
    109
    Location:
    Castle Rock, CO
    I installed twisted throttle motech front engine guards. Happy with them and did some research on them. Bark buster hand guards were installed too. Both have already came in handy. I have kept a Givi 52 tail bag around for my last three bikes. Real happy with the bag. Comes off easy and holds two helmets. Comes with back rest support option too.
    I would go next time with soft side cases and not the happy trail bags. They are the old style HP bags though. New ones are much better.
  11. PWRCRZR

    PWRCRZR Grumpy Old Bastard

    Joined:
    May 10, 2008
    Oddometer:
    7,699
    Location:
    Mid-Coast Maine
    I haven't seen any 12.9 break but again it depends on a lot of other variables. I often load my KLR down with entirely to much stuff then go pound it around all of our trashed back roads, dirt and gravel. So once mine broke I went for what seemed like the strongest repair I could make.
  12. hoyks

    hoyks Tightass KLR rider

    Joined:
    Jan 11, 2008
    Oddometer:
    814
    Location:
    SE Qld.au

    A mate bought me one of these on special. He used to cable tie his lid to the bike, but came back one day to find spit and cigarette buts in it:puke1..... he worked at the unemployment office, so maybe he offended someone.

    It rolls up in a bag not much bigger than a pair of socks*


    *Long, thick woolen work socks, but still a pair of socks.

    http://pacsafe.com/lidsafe-anti-theft-helmet-bag

    [​IMG]
  13. firewatermetal

    firewatermetal Adventurer

    Joined:
    Oct 12, 2009
    Oddometer:
    32
    Location:
    Arkansas
  14. IDRIDR

    IDRIDR Take me to the River

    Joined:
    Jun 16, 2010
    Oddometer:
    1,575
    Location:
    Boise, Idaho
    So while working on the '06 yesterday, doing subframe bolts and other items, I pulled the carb to check it out. Pretty clean which was good to see. Jets were stock (main #148, pilot #40). Pilot screw cap was off and set to 1.5 turns out.

    The main jet wasn't even finger tight :huh. Just a little effort and it backed right out. Yikes! There was a bad day in my future if I'd not found that. Anyway, gave it a spray with carb cleaner and blew out passages, did the 22 cent mod with a 0.028" thick washer, drilled slide to 7/64", set the pilot to 2 turns out (but plan to play with this later and find the correct setting), and replaced the phillips head screws with allen cap heads. Replaced the enricher with one of the brass cable eliminator units. Thought of trying the KLX250 enricher, but like the idea of this piece actually designed for the carb with the ability to hold choke position mid-range, whereas the KLX250 enricher is either on or off.
    http://www.ebay.com/itm/KAWASAKI-KL...Parts_Accessories&hash=item19cc495de9&vxp=mtr

    Good weekend in the shop. Any thoughts on the above carb work, good, bad or indifferent? What do ya'll do with the stock choke lever when you use a cable eliminator? Leave the lever up there and plug the holes with silicone to keep the dust out, or are there better options?

    Thanks to those who have offered advice, either here open in the forum or by PM. Much appreciated. :clap:clap
  15. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    3,708
    Location:
    Garden City, Michigan
    How do you like the enrichener off ebay?? Did you see the one Stead engineering has?
  16. IDRIDR

    IDRIDR Take me to the River

    Joined:
    Jun 16, 2010
    Oddometer:
    1,575
    Location:
    Boise, Idaho
    Fits nice, looks sharp, but it will be a while before I actually get to try it. I'm guessing at least another month before the bike is back up and running. I did see Stead's unit, but decided on the fleabay one because it has adjustable friction and was plug-and-play without the need to use any of the old spring and piston parts. "OVER 150 SOLD WITH ALL GOOD FEEDBACK,SO BID WITH CONFIDENCE"
    I hope in the end I'm just as happy as the rest of their customers.
  17. GAS GUY

    GAS GUY MILE EATER

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    Jul 27, 2007
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    I see it has adjustable friction,but does it still click in on and off position with a positive detent feel ?
  18. IDRIDR

    IDRIDR Take me to the River

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    Jun 16, 2010
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    1,575
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    No, not positive feel like the KLX250 unit. It slides smoothly through the whole range, which I can see as a potential drawback to not knowing if it is fully closed. There is a non-adjustable version for a few bucks less, but I don't know if it has the positive detent feel.
  19. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
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    Location:
    Garden City, Michigan
    Actually, that should be fine, as that is how the stock unit works also.
    I am considering this mod, I am going to have to throw my 10 gallon tank on and make sure I will be able to get to it.
    Can you post a picture of it on your bike ? Also how many inchs does it stick out from the carburetor?
  20. IDRIDR

    IDRIDR Take me to the River

    Joined:
    Jun 16, 2010
    Oddometer:
    1,575
    Location:
    Boise, Idaho
    Yes, I can do that. The other model they sell is a little shorter I believe.