KLR650 Only Thread......

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

  1. tac650

    tac650 Broken...

    Joined:
    Oct 9, 2004
    Oddometer:
    816
    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?
    PapaWolf likes this.
  2. PapaWolf

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

    Joined:
    Dec 29, 2014
    Oddometer:
    288
    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.

  3. DSquared

    DSquared Dilly Dilly!

    Joined:
    Mar 13, 2015
    Oddometer:
    1,676
    Location:
    Burlington, WI
  4. John Fry

    John Fry Adventurer

    Joined:
    Jan 4, 2009
    Oddometer:
    38
    Can anyone confirm if the rear footpeg brackets off a 2012 will fit on a 2008?
    Bike Bandit shows different part numbers.
  5. Bell driver

    Bell driver Long timer

    Joined:
    Apr 21, 2010
    Oddometer:
    1,194
    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.
  6. John Fry

    John Fry Adventurer

    Joined:
    Jan 4, 2009
    Oddometer:
    38
    That's what I thought. Thanks
  7. k5mitch

    k5mitch Been here awhile

    Joined:
    Jul 11, 2013
    Oddometer:
    673
    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.
  8. HardWorkingDog

    HardWorkingDog Harvey Mushman

    Joined:
    Aug 20, 2009
    Oddometer:
    2,997
    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]
  9. Pollack

    Pollack Adventurer

    Joined:
    May 31, 2014
    Oddometer:
    875
    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,
  10. Pollack

    Pollack Adventurer

    Joined:
    May 31, 2014
    Oddometer:
    875
    I picked up the HF version for $75 a couple years ago and it has worked without any issues.

    Best regards,
  11. EnduroRdr

    EnduroRdr Woods Racer & D/S Rider

    Joined:
    Feb 15, 2008
    Oddometer:
    2,492
    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
  12. Pollack

    Pollack Adventurer

    Joined:
    May 31, 2014
    Oddometer:
    875
    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,
  13. k5mitch

    k5mitch Been here awhile

    Joined:
    Jul 11, 2013
    Oddometer:
    673
    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
    Pollack likes this.
  14. k5mitch

    k5mitch Been here awhile

    Joined:
    Jul 11, 2013
    Oddometer:
    673
    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
  15. Grinnin

    Grinnin Forever N00b

    Joined:
    Dec 10, 2005
    Oddometer:
    5,000
    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.
  16. Blackheart

    Blackheart Adventurer

    Joined:
    May 16, 2012
    Oddometer:
    49
    For years I've been using the discontinued Harbor Freight Lightweight Aluminum Motorcycle Lift ( Item #94715)
    [​IMG]
    It was less expensive than the Sears equivalent model yet the locking pin mechanism is a safer and superior design than Sear's.
    [​IMG]
    I've done all my maintenance while the bike is on this jack and it does'nt wobble.
    Always lock the jack by inserting the holding pin then lower the jack onto the pin. That removes pressure from the jack's hydraulic seals, extending the life of the seals.
    [​IMG]
    Since owning the jack in 2011 when parking my 2008 KLR at home it goes up on the jack, only when out on the road do I use the side stand. Chain cleaning and oil changes are much easier. Though I have no scientific proof I think the fork seals and rear shock have lasted longer by parking the bike up on the jack, which relaxes their internal pressures.
    thechief86 likes this.
  17. Grinnin

    Grinnin Forever N00b

    Joined:
    Dec 10, 2005
    Oddometer:
    5,000
    Location:
    Maine
    Does that lock at only 1 height? The steel lift locks at 3 different heights which is handy for doing different kinds of work.
  18. thechief86

    thechief86 Been here awhile

    Joined:
    Sep 5, 2015
    Oddometer:
    983
    Location:
    White House, TN
    Picking up this sexy beast tomorrow morning for a VERY good price, will need to swap the head, but I'm hoping the piston and cylinder are ok.
    If not, I guess it'll sit for a few weeks while I come up with the dough for a 685 kit.
    Street tires will remain, at least for a little while. This will be my commuter, as I already have a very decent street legal dirt bike :cool: 50/50 tires will come when these wear down or I have some disposable income, whichever comes first, lol. :rolleyes:

    IMG_0943.jpg
    GreatWhiteNorth likes this.
  19. Bigger Al

    Bigger Al Still a stupid tire guy

    Joined:
    Oct 12, 2004
    Oddometer:
    8,933
    Location:
    Auburn, CA
    PlowHand and thechief86 like this.
  20. Subcanis

    Subcanis Dental Floss Tycoon

    Joined:
    Jun 7, 2006
    Oddometer:
    1,398
    Location:
    The Friendly Ghost
    My dad's bike died this summer in the middle of the White Rim. Same symptoms. EVERYTHING tested within specs. Started swapping parts from my bike over to no avail. He wound up getting a smoking deal on a used stator, flywheel, and case cover w/pulse coil on EBay (found a hairline crack in the case while troubleshooting). Decided to swap everything out, because why not. Fired right up. Bench tested the old parts again, found no issues.

    Glad it worked, but soooooooo frustrating to not know why the originals were NFG.
    GreatWhiteNorth likes this.