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  1. Looking at a 2004 klr 650 with 20000 kms 12 500 miles. This will be my first street legal bike. I’m 43 200 lbs and I’ve been riding dirt bikes most of my life. As the bike is 17 years old is there any reason I should shy away from it and look for a newer one? I
  2. Just installed an FMF system (powerbomb header & Q4 slip on) on my ‘05 KLR 650. Used contact cleaner and Permatex copper high temp silicone on both ends of the header. Got it up to operating temp and noticed a thin steady stream of white smoke where header and slip on meet. I idled the bike at operating temp for about 5-10 min and it didn’t produce any more/ thicker smoke so My best guess is probably something in/on the pipe burning off, probably nothing serious but i am curious as to what this might be?
  3. Hey guys I’ve had my tail after about 10 years and all of a sudden the other day I have oil coming out of the bottom... I believe these photos are the overflow any help would be fantastic I think I’ve overfilled the old girl
  4. What are the best used Dual Sport models to convert into a scrambler style? Looking for 400-650cc, decent Highway Speed (cruise around 65-70 mph), Low Maintance, good MPG, can handle long distance rides (150 mile day ride), Very Good on fire roads, decent single track, can handle occasional sand and rocks no problem, lighter weight, Currently deciding between: drz400 and 650, KLR650, XR400R 600R and 650R,
  5. Bought an 05 KLR about 6 months ago put over a thousand miles on it since. Decided it was time to check the valves as part of regular maintenance considering I don’t know the last time they were adjusted. All valves were tight, pulled the cams and replaced the shims. Valves are now running at the loose end of spec. Exhaust valves can get a 0.25mm feeler gauge under with some friction, a 0.30mm won’t get in there at all. Same with the intake: can get a .20mm gauge under but a .25 won’t at all. Engine is timed correctly (I checked at least 5 separate times) and the cam chain tensioner was reset before bolting it back on. The bike had some ticking noises coming from the top end before doing this adjustment, however since doing this the ticking noises have become much louder. As with the quieter ticking the noise is there right from the start, when bike is in neutral, and does not get louder or or quieter with low to mid range RPMs or engine temperature. The only time it seems to disappear is at high RPMs or speeds where the exhaust drowns out the noise. No difference in power or the way the bike runs/ rides. Also worth noting I stripped the right intake valve cover thread (that’s a whole nother post in itself lol). I know KLRs are noisy machines but this seems to be a bit much. I don’t want to write it off as it being a typical KLR noise, I plan to get as much life out of this bike as possible so I’d like to know 1) is this a product of loose valves? 2) something else, or something to be concerned about? 3) has anybody else experienced this? 4) How the hell do I get rid of it? thanks in advance, KT
  6. Hey all, I have a new (to me) KLR650 and I’m looking to do some minor upgrades. I’d like to put on a new header and muffler, specifically the FMF powerbomb header with a Yoshimura RS2 comp muffler. More or less for weight reduction and looks. I know I’ll need to do some jetting, just curious if anyone can point me in the right direction on how to determine what jets to buy? What brand etc
  7. What up my people! So I have an 03 Klr and I'm thinking of converting the headlight to a round headlight attached to the forks with brackets and also upgrading the instruments cluster to a Vapor digital reader. Does anyone have any experience with this and if so are they mostly plug and play or would I need to cut some wires and do some fiddling with the connections?
  8. I'm going to look at a 2015 KLR 650 in a few days. The owner says it has around 3000 miles on it and it's been sitting for a few years and won't start. Never been crashed so I assume I can drain the gas, rebuild the carb and get a new battery and it should be fine. What else should I be looking for and what issues should I expect going forward? Not sure exactly what I should offer but with it not running i'm thinking I should get it pretty cheap or just pass seeing as how I can get 1 same year with similar miles for pretty cheap already. Any advice would be much appreciated.
  9. Hello everyone. First time KLR 650 owner here. Picked up a 2022 Adventure model today. Pulled the trigger based on Tu’s YouTube review from 3D Cycle Parts as I was impressed with how he was able to take the bike off-roading. I’ve spent 15 to 20 mins total riding the bike in a parking lot. I’m coming from a 2022 CRF300L and haven’t ridden regularly in over 20 years. The CRF300L is a bit underpowered and a bit small for my tastes. However, it is a gem of a bike that I may keep. I consider myself an advanced novice and for ref sake I’m 5’ 11” / 210ish (without gear). Buying experience was smooth with less than $700 dealer markup. Doesn’t seem to be a lot of demand here in So Cal for the 2022. At least not as much as the CRF300L / Rally. The dealer had all 3 colors and 2 base / 1 adv model. Chose the adv model as it offers quite a bit for only $1k. In my opinion biggest reason to choose the adv model is the killer led fog lights, usb / 12 volt ports, side hard case mounts (not the hard cases), and the frame sliders. If you like to tinker I suppose with free labor $1k can buy a decent amount of diy upgrades. Dislikes: 1. Side hard cases are tiny (don’t let factory pics fool you, rated to hold only 11 lbs each, and feel unbelievably cheap (like the plastics were sourced from a budget toy factory). 2. Rear aluminum rack has weight limit of only 20lbs. 3. Bike has some shiny plastic trim which I don’t get on a dual sport / adv bike. The matte camo is great, but I wish It was matte throughout . 4. Overall weight is a bit of a head scratcher. I really don’t understand why this bike weighs so much. 5. Clutch is pretty good, but CRF300L slipper clutch is just butter. Likes: 1. Led fog lights are fantastic. I estimate they double light output. 2. Bike is very comfortable and smooth. Seat and seating position is perfect for me. I can see riding this bike long distances. 3. Love the engine. Nice and torquey with the beautiful thumper exhaust note / sound. 4. Price - obviously used would be the way to go, but I’m not experienced enough to judge a used bike. 5 year old KLRs are selling for $5k to $6k. A significant savings from out the door price on new, but I’m planning on keeping long term so ok with new. Really nothing else at this price point. Neutral: 1. Weight: The bike feels lighter than its stated 487 lb weight. It’s reasonably well balanced, but that weight shows itself at times (e.g. trying to push it up a slope) or loading / unloading from a trailer. Overall I’m not too bothered by it and surprised that I’ve adjusted to it almost instantly. 2. Suspension: It’s good for now, but will need some tuning. Little bit on the spongy side, but not too bad either. 3. Tires: too early to tell, but I will likely change to more aggressive tread. Overall I suppose a fair amount of bike for what Kawasaki is charging. It doesn’t have the mechanical / precise feel of a Honda, but instead feels like a Japanese Chevy Silverado. I say that in a loving way as I have a Silverado. I get it as to why this bike has a cult following. Need to tweak it to my tastes (panniers, suspension, doo hickey fix, etc) Kicking myself for not buying a KLR 20 years ago. Cheers
  10. Alright riddle me this - 1997 KLR 650, runs perfect except over 65 mph, then the RPM surge, I can not feel any change in the actual power, and the MPH climb in a consistent manner all the way to 80, but 65-80 mph the rpm bounces from 5000-9000 erratically. I have changed the ignition coil , which I ordered from 3d assuming the first thing, leaking sparks over to the sensor. I have looked for loose connections thinking maybe something was not grounding and causing it to jump, but everything is clear. But now I am out of guesses.
  11. My 2012 klr 650 makes a hissing/ scraping noise when pushed forward it becomes louder when riding and sometimes makes a click consistent with the revolutions: It only has 6,000 miles on it. It does sit sometimes and collects sawdust like a motherf***** that I clean off with compressed air but sometimes I don’t clean as often as I should. So should I grease or be tightening anything?? This noise doesn’t need brakes applied to happen but it does get worse (the hissing/scraping) when brakes are applied.
  12. Just installed an FMF system (powerbomb header & Q4 slip on) on my ‘05 KLR 650. Used contact cleaner and Permatex copper high temp silicone on both ends of the header. Got it up to operating temp and noticed a thin steady stream of white smoke where header and slip on meet. I idled the bike at operating temp for about 5-10 min and it didn’t produce any more/ thicker smoke so My best guess is probably something in/on the pipe burning off, probably nothing serious but i am curious as to what this might be?
  13. I was wondering how would I go about converting a KLR650's single exhaust tip into dual twin tips for under 200$ (example picture below). Is there a pre made system already made?, are there converters and other pipes pieces I can put together to build it?, or is something I have create entirely on my own by cutting and bending pipes? thanks
  14. My 2013 KLR650 has 8K miles on it. The other day I tried to start it and all lights came on when I turned the key on. When I pushed the starter button all power went off and I heard a faint crackling sound. I had no dash lights, headlight, brake light, turn signals or horn. ALL POWER was gone. I checked the main fuse (not the spare underneath in the rubber holder) and the two fuses under the seat with a fuse tester and the test light came on for all three. I took the key in and out, wiggled it around, turned the bars back and forth and still no power. Today I started to troubleshoot again. I turned the key on first just to start from the beginning and all lights came on. But when I pushed the starter button everything went off again and I heard that very faint crackling sound again. What do some of you electrical gremlin chasers think my next move should be?
  15. looking at one 2010 with 45000 miles on it. very clean. is that way to many miles? 2700 price? KLR650. Black and green
  16. So I’ve been driving the KLR for 6 months trying to troubleshoot this problem With no luck so I’ve decided to come to the experts. It seems to only happen when the bike is warm. I’ll be riding along at between 45/70 mph and the bike will just drop RPM to 0. Then I’ll let it rest for about 3/5 mins and it will start Again ride for another 5 miles until it dies again and repeat till I make it home. It doesn’t seem like a fuel suction problem because I’ve had that problem in the past and I’d lose power before it died. I also just replaced my petcock. Adjusted the valves replaced the spark plug. And put the KLX needle kit in. So if y’all have any ideas I would love to hear them!
  17. Howdy. I'm hoping to find information on Engine ID numbers for the 650. My bike is a 1999 KLR 650 with 50k miles on the ODO. The previous owner told me that he replaced the original engine with an engine from a 2008 model, after the 99' engine doohickey exploded. After taking apart the stator side case and changing gaskets I found that the Balancer Chain is worn out, and almost out of adjustment. He possibly used the 08 engine crankcase and the outer covers from the original 99 engine.. I'm doubtful... I'm trying to find an ID list that shows the Engine Numbers for model year KLR's. I had found a website in the past with the info but cant seem to find it anywhere now. The crankcase currently in my bike has the Engine Number ID KL650AEA39124. 08 or 99? Thanks.
  18. I am turning an '03 KLR650 into a scrambler, and I am trying to dress it up a little bit. Is there any reason that I can't swap whole lever/perch set ups from another dirt bike and make it work? I feel like they all work essentially the same, but I'm really guessing. Anybody know for sure?
  19. Just bought a new to me '15 with 7300 on the clock. Overall in good shape, some cosmetic nicks and scratches. Paid an okay amount, could've maybe gotten it for a little less, but around me low mileage are hard to fine. Anyway, there is something I missed when I was checking it out. I neglected to go full lock left and right, mostly because it was pissing down rain when I test rode it. The issue is when it's full lock right, it catches a plastic tab like piece that's perpendicular to the fairing. I almost wonder if fairing or the brace behind the fairing is off kilter. It doesn't seem to be when I eyeball it, but it's my first KLR (actually more for my son), but it absolutely has the fork catching this piece. The left side is not at the same angle and almost seems shorter. I'm attaching pictures, as best I could take. Could someone give me some insight? Thanks in advance.
  20. Hello I had been using, and was happy with, the CVK40 carb on my DRZ400. Happy and should have left it alone. I saw that you could replace the plastic inlet with a brass elbow and thought it made sense to do it preemptively. I am trying to build my DRZ into some sort of bulletproof apocalypse machine and cant resist a $10 upgrade in the name of reliability. The consensus out there seems to be that pulling the old piece is the dangerous part. I got it out without much hassle. I carefully tapped the new piece in to get it started and then used a bench vise to slowly press the new one in. It went in half way and then "tink" a split appeared running along with the insert. I was very pissed because that carb was clean and setup nicely. Worked very well. I didn't even consider trying to see if it leaked because I just would be driven nuts by it, so I ordered another used carb of Ebay. And then the exact same thing happened. THis time I tried heating the carb body and cooling the brass piece with freeze spray. Exact same thing. So now I'm into it for $350 and wanna scream. I don't think I'll try it again, but out of curiosity has anyone done this job and had anything similar happen. Any advice other than stop F'ing around with things that aren't broke?
  21. So what's the deal with this one? I thought these were converted to run off Diesel. This doesn't appear to be converted over. So is it a fake? I blocked out the sellers name/number just for privacy reasons. Plenty of misspells can be the sign of a scammer. Or maybe it's legit? Any input on this bike would great. Thanks!
  22. From Kawi: ESCAPE. EXPLORE. ENVY. For 2022, Kawasaki welcomes the return of the widely popular and critically acclaimed all-new KLR®650 motorcycle to its lineup. The legendary dual-sport bike is back and better than ever, refined and ready to make new memories. Featuring new technology you’ve been waiting for, and the same reputable reliability, the KLR®650 is ready for your next expedition. Whether it’s traveling long distances or making the daily commute, this adventure-hungry, on-and off-road machine offers the versatility and toughness required to accommodate any adventure. The all-new 2022 KLR650 receives the addition of fuel injection to the 652cc single-cylinder engine offering increased reliability and fuel efficiency. A new multi-functional digital instrumentation panel with a fuel gauge is paired with a new fuel tank design with greater useable volume. Numerous parts have been updated for increased riding confidence when carrying luggage, reduced vibrations, and increased generator capacity, contributing to the improved performance and ride comfort that is needed when searching for a tough adventure partner. The all-new KLR650 features a new LED headlight, is available with optional ABS, provides a terrific riding position for all-day riding comfort and boasts plenty of carrying capacity. For 2022 the KLR650 motorcycle will also be available in two new special editions featuring a number of Kawasaki Genuine Accessories including side cases, engine guards, LED auxiliary light set, and more. 2022 KLR650 HIGHLIGHTS · NEW Fuel Injected 652 cc Single-Cylinder Engine · NEW Multi-Functional Digital Instrumentation With Fuel Gauge · NEW LED Headlight · NEW Bodywork including fuel tank · NEW Larger Front Disc And Optional ABS · NEW Greater Wind Protection and Styling · NEW Increased Carrying Capacity ENGINE · NEW Fuel Injection · NEW Revised Cam Profiles · NEW Exhaust Pipe Diameter · NEW Updated Clutch · NEW Increased ACG Output · NEW Low Maintainence Battery · NEW Lighter Starter, Ignition Coil, And Evaporator Canister · NEW Honeycomb Catalyzer The KLR650 is powered by one of the most well-known, reliable, and trusted engines in the motorcycle industry. Its liquid cooled, four-stroke, 652 cc single-cylinder engine features a DOHC cylinder head and produces a flat power curve that lets you navigate challenging roads and cruise at freeway speeds . The 2022 model is now equipped with fuel injection, which, combined with the fuel tank’s greater useable volume, contributes to an increased range between fuel stops, while updates for increased durability ensure the reliability expected of an adventure tourer. Featuring fuel injection for the first time, starting the KLR650 has never been easier, especially at high altitude or in cold conditions, and its reliability and performance have been increased. A 10-hole fine-atomizing injector sprays 60 µm droplets, which contributes to efficient air-fuel mixing for efficient combustion. Revised intake and exhaust cam profiles improve mid-range power and torque characteristics. A stronger cam chain guide material and shape add to the increased reliability. The exhaust pipe diameter has been reduced by 7.7 mm to improve mid-range torque characteristics to better suit everyday riding. An oxygen sensor provides feedback to the fuel injection system, contributing to cleaner exhaust emissions and increased fuel efficiency. Several updates have been made to improve shifting feel and reduce weight. In the clutch and transmission, the clutch release bearings were changed from ball to thrust-needle bearings, the gear dogs and shift fork have been revised on third gear, and a new finishing treatment is now used for fourth and fifth gears. A new sealed battery adds to the convenience and is significantly lighter than the previous battery. The starter, ignition coil, and evaporator canister have all been revised and are now lighter than on previous models. CHASSIS · NEW Rear Frame · NEW Swingarm · NEW Larger Swingarm Pivot Shaft The KLR650 motorcycle’s proven and high tensile, semi-double-cradle frame receives several updates on the 2022 model. The updates now include a rear frame that is integrated with the main frame to increase torsional rigidity for a more composed ride and a 30mm longer swingarm with a 2mm larger diameter swingarm pivot shaft that also contributes to better handling. SUSPENSION & WHEELS · NEW Front and Rear Suspension Settings · NEW Larger Front Brake Disc · NEW Thicker Rear Brake Disc · NEW Optional ABS Models · NEW Stronger Rear Wheel Rim Material · NEW Larger-Diameter Axle Shafts Both front and rear suspension settings complement the new frame to help provide a more planted feel. In order to meet the demands of both on and off-road riding, 41 mm front forks with 200 mm of suspension travel handle the suspension duties up front and add the rigidity needed for superb performance. Firm fork springs provide excellent bump compliance and bottoming resistance while also reducing front-end dive under heavy braking. An adjustable Uni-Trak® system with 185 mm of suspension travel can be found on the rear and complements the front fork settings, offering progressive rear suspension action while contributing to a low center of gravity. Firm rear shock settings help resist bottoming in rough terrain and accommodate heavy loads. Rear spring preload and rebound damping adjustments allow riders to fine-tune suspension settings to suit the riding conditions and rider’s preference. The front fork and rear shock settings complement each other for light, sharp handling on smooth roads while providing the capability needed off-road. Complementing the KLR650 motorcycle’s more powerful engine is a larger 300mm front brake disc that delivers more substantial braking power. The disc shape has been changed from a petal-type disc to a round disc, adding to its tough appearance. On the rear brakes, the disc has been thickened to provide better heat dissipation when under heavy braking. Similar to the front, the back disc shape is now round. Models with and without ABS are now available and the ABS offers additional rider reassurance when riding on low-friction surfaces. The KLR650 comes equipped with a 21” front wheel and 17” rear wheel that allows riding to be continued even when the paved road ends. A stronger material can now be found on the rear wheel rim, delivering improved torsional rigidity and increased durability. The front and rear tires are tube types, making it possible for the rider to carry out any necessary roadside repairs. A larger-diameter front and rear wheel axle contribute to both durability and handling. ERGONOMICS · NEW Fine-Tuned Handlebar And Footpeg Positions · NEW Rubber Mounts On Handlebars And Footpegs · NEW Fuel Tank Design With More Useable Volume · NEW Taller Windshield For Increased Wind Protection · NEW Seat Design And Materials For Improved Comfort · NEW Pillion Grab Bars For Passenger Comfort · NEW 30 mm Shorter Side Stand The KLR650 has long been known for its comfortable, upright riding position, and for 2022 it has been fine-tuned to deliver a stress-free position for a longer adventure. One significant improvement has been the reduction of vibration from parts that come in contact with the rider, further contributing to comfort when on long rides. Fine-tuned handlebar and footpeg positions have each been moved 10 mm outwards to provide adjustability and put the rider in a slightly more relaxed position, to support longer hours in the saddle. The handlebars and footpegs are now rubber-mounted, reducing vibration for improved comfort. A new fuel tank design has been fitted to the KLR650 chassis, offering a natural fit with the rider’s knees for comfort and increased controllability. While the volume of the new fuel tank remains the same, the useable volume has been increased through redesign and a new fuel pump that draws from the very bottom of the tank, contributing to a longer cruising range. Aiding the rider up front, a new stylish windshield can be found, which is now 50 mm taller for better wind protection and features two-position bolt-on adjustability that allows windshield height to be conveniently increased a further 30 mm. The seat shape and cover have been revised and the optimized urethane thickness and firmness all contribute to increased ride comfort. Under the seat, rubber dampers have been added to further aid in rider comfort. Passenger grab bars have been reshaped, improving passenger comfort. The side stand has been shortened 30 mm, making it easier to deploy when on the bike. BODYWORK & STYLING · NEW Shroud, Side Cover, And Tail Cowl · NEW Bright LED Headlight · NEW Taillight And Turn Signal · NEW All-Digital Instrument Panel · NEW Longer Mirror Arms The KLR650’s robust design reflects the bike’s capabilities for an unforgettable adventure. New colors and textured graphics were specially chosen to emphasize its ruggedness. Its modern styling includes a protector-equipped shroud design that contributes to a functional and rugged image, while a new side cover design and tail cowl tie the robust styling package together. In addition to the windshield offering increased wind protection, it also adds to the tough adventure tourer appearance that Kawasaki engineers set out to achieve on the KLR650. A new bright LED headlight illuminates the way when the ride continues past sunset and also contributes to the intended adventure styling. In the back, a revised taillight and turn signal design add to the tough styling. Rearward field of vision has been improved thanks to longer mirror arms. An all-digital instrument panel offers information at-a-glance through a large display and easy-to-read LCD screen with white backlighting. The instrument panel features a speedometer, odometer, dual trip meters, fuel gauge, clock, and indicator lamps. The narrowed-down display list prioritizes visibility of the speedometer and fuel gauge. ACCESSORIES A number of Kawasaki Genuine Accessories (KGA) will allow riders to personalize the looks of their KLR650 and offer added comfort and convenience. Kawasaki accessory side cases and top case were developed to provide a clean look with their well-matched design. The side cases feature a top-opening design that makes it easy to add and remove items when they are mounted on the bike. The side cases easily clip onto their mounting brackets for a secure fit. The top case is large enough to accommodate an off-road style helmet. Improving convenience, side cases and the top case can be fitted with a one-key system. Complementing the accessory luggage, a larger aluminum rear carrier offers improved carrying capacity. In addition to its exclusive luggage, accessories include grip heater set, LED auxiliary light set, engine guards, DC power outlet, and USB socket. SPECIAL EDITIONS Also new for the 2022 KLR650 are two model variations that feature factory-equipped accessories and both come standard with ABS. The KLR® 650 ADVENTURE model comes equipped with factory-installed side cases, LED auxiliary light set, engine guards, tank pad, and both DC power outlet and USB socket and is available in the Cypher Camo Gray colorway. This model is designed for the adventurer who is looking for increased carry capacity and convenience. The KLR® 650 TRAVELER model features a factory-installed top case and both DC power outlet and USB socket and comes in Pearl Lava Orange colorway. COLORS The 2022 KLR650 is available in Pearl Sand Khaki and Pearl Lava Orange. The KLR650 ABS is available in Pearl Sand Khaki. The KLR650 ADVENTURE model is available in Cypher Camo Gray and the KLR650 TRAVELER model is available in Pearl Lava Orange. MSRP KLR650 – $6,699 KLR650 ABS – $6,999 KLR650 TRAVELER – $7,399 KLR650 ADVENTURE – $7,999
  23. Hey guys i have a 2015 kawasaki klr650, just put a lexx exhaust on it and i bought the klx jet get from eagle mike, just not sure were to go from here. I will be drilling the slide and removing the snorkel from airbox, i am at about 600dt elevation and northern temperature's in canada. What jetting should i go with and what needle clip on the klx needle? How many turns on the idle screw? The lexx exhaust has the spark arrestor removed, i also bought a 42 pilot jet that was recommended
  24. When moving the lever the choke cable goes out of the housing and doesnt actually move the inside cable, but rather the entire cable piece. Will a new housing fix this? Want to keep cable choke, not go for an eliminator. I'm wondering if it will have the same problem even with the new housing. Don't really know how the cable is supposed to stay in the housing anyways.. Is it glued?
  25. Hi all, My Uncle recently loaned me his (unused since fall of 2014) 2001 KLR650. Said it has a fuel leak (which I haven't found - must need to be running) and otherwise needs a battery. Shift lever also looks questionable, as if the weld may break, so looking to buy that and the choke cable delete kit. my big question is -- and yes I searched for about 40 mins on here -- where do you buy parts for these bikes now? The TT store doesn't carry parts for these bikes?
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