Welcome, Guest. Please Login or Register

Author Topic: KLR650 Restoration....Please help......and mods :)  (Read 28177 times)

0 Members and 1 Guest are viewing this topic.

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......and mods :)
« on: February 23, 2007, 07:44:06 pm »
Hi Guys

I picked up a 2005 model KLR650 in PE for a good price, but it needs some work to be perfect again.

Since there are so many KLR owners on this website i was wondering if you guys could give me a few answers.

The bike has done 43000kms but mostly on tar so its quite neat.

What would the following replacements cost me?

1. Front tyre? What should i buy, bike will mostly run on tar and good gravel.

2. Front and rear brake disks and pads? The current units are still working but they are worn.

3. Front and rear sprockets and chain? What should i buy? The chain is a bit slack and the sprockets worn quite deep.

4. Leaking front shock? What would the replacing of the seals cost?

Thanks
Captain Slow
« Last Edit: March 15, 2008, 04:38:37 pm by CAPTAIN SLOW »
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

shark_za

  • Guest
KLR650 Restoration....Please help......
« Reply #1 on: February 23, 2007, 07:52:21 pm »
All basic maintenace items, should not cost too much, although doing it all at once adds up.

For a chain and sprocket, any 520 o-ring chain, probably about R400.
Sprockets, from Kawa, check for new pricing.

Do your disc's really need replacing? Or just the pads?
Pads are cheap, say R80-R100 for each brake.

I like a more offroad tyre, but for lots of road look at the Trailwings.
Fronts are cheap, expect to pay around R400-R500.

Fork seals, not sure on price, but reasonably cheap.
 

Offline sidetrack

  • Keep it real, keep it a single
  • Gentleman Dog
  • *
  • Bike: Yamaha XT 660 Z
    Location: Gauteng
  • Posts: 15,563
  • Thanked: 568 times
KLR650 Restoration....Please help......
« Reply #2 on: February 23, 2007, 08:54:29 pm »
Don't skimp on the chain, buy a good o or X ring otherwise expect to adjust it every other ride or worse it snapping like LouisXander's did  :shock: Oh yeah and congrats, let us see a pic of your KLR !
Little by little, one travels far
J.R.R Tolkien
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #3 on: February 23, 2007, 10:19:45 pm »
I'll post some pics tomorrow. If everything goes allright.
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #4 on: February 24, 2007, 01:55:44 pm »
Part Description   Cost
Front sprocket   R 120.00
Rear sprocket   R 220.00
O-ring chain   R 450.00
Fork seals   R 160.00
Front disk   R 1,470.00
Rear disk   R 940.00
Brake pads front   R 180.00
Brake pads rear   R 180.00
Spark plug   R 20.00
Air filter   R 250.00
Front tyre Bridgestone Trail wing   R 480.00
Rear tyre Bridgestone Trail wing   R 650.00
Labour 3 Hours   R 600.00
Total   R 5,720.00

These prices are all from a Kawa dealer, except the tyres.
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #5 on: February 24, 2007, 02:15:57 pm »
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

Offline Jaqhama

  • Race Dog
  • ***
  • Bike: Kawasaki Super Sherpa
    Location: Australia
  • Posts: 619
KLR650 Restoration....Please help......
« Reply #6 on: February 24, 2007, 03:30:58 pm »
Hey Captain KLR?

You could easily save yourself the R600 labour by finding someone (from the forum?)  who is familiar with working on bikes.
Believe it or not most of the stuff you want to replace is a fairly simple operation.
But you will need someone who has done this kind of work on bikes before.
I am assuming you have not?

How badly are the sprockets worn?
When they wear the points of the sprockets lean forwards in the direction of wheel travel.

You probably don?t need to replace the discs mate, just the brake pads.
Hard to imagine the dics are already worn thru on a 2005 model?

Perhaps you could find a forum member who is familiar with the KLR and lives near you?
Run the bike over to his place and get a second opinion for the stuff that needs to be replaced?
I am not making a comment on SA bike shops?but it?s obviously to a shops advantage to point out things that are worn on a bike and suggesting those things need to be replaced.
I am not saying they do not need replacing, but perhaps some of those parts may last for a few months yet.
I understand that the brakes on a KLR are nothing to get excited about, even when they are brand new.
Remember you are coming off a sports bike?which  probably had far superior brakes.

The front fork seal will need to be replaced however.
Make sure you change the oil in the forks, people leave the fork oil in bikes for far too long.
Some nice clean oil will make a world of difference.

Air Filter...get a UNI-Filter...they are made to be washed and used many times over. I am sure they make one for the KLR.

Front tires last a lot longer than rear tires, you also don?t need a super expensive one for the kind of riding most KLR owners would do.
Bridgestone normally have some very cheap tires, I use them on my own bikes.

I really reckon you need another trail bike owner to have a look and advise you about the things on your list that need replacing mate.

Pity I?m not in SA yet?I would have done all the work on the bike for you mate.
One full day would probably see it all done.

You should also change the engine oil, and install a new egine oil filter.

You just need the tools and someone who is used to working on his own trail bike.
DON?T attempt the work yourself if you have absolutely no idea what you are doing.

Once you have helped someone change chains and sprockets, it?s easy.
Same for discs and brake pads.
Etc.

Hope some of this helps.
Sure a few blokes on the forum have suggestions also.

Cheers: Jaq. (also a SA KLR owner apparently.)
It's not just a mode of transport, it's a fking adventure!
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #7 on: February 24, 2007, 04:15:58 pm »
Hi Jaq

Go look on the BikeSA forum, i have touble posting pics here.

There is a pic of the sprocket.

The chain is screwed man. I'll rather replace now while i have the money.

Disks, i'm only replacing the front disk and pads. The rear is okay.

Yes i am used to the single finger stopping ability of the Gixxer that i had. But i still want to see if the new disk and pads won't make it better. The bike has done 43 000kms on tar remember. It really needs new front brakes. The disk has about a millimeter groove on each side and in between there are smalle grooves. Almost like its been metal on metal. You know what i mean.

The fork seals i'm gonna get done at the shop as i dont have all the tools for the job. I will put new oil in.

As to mechanical work. I've got quite alot of experience with that. I'm an engineering student remember. Its just that i've never worked on bikes before.

I allready ordered, front and rear prockets and chain. Front disk and pads. Fork seals.

I'll have a look later on the disk and pads and even sprocket and chain i'm considering to do myself. But i don't know about the fork seals.

Thanks for the info Jaq
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

Offline Jaqhama

  • Race Dog
  • ***
  • Bike: Kawasaki Super Sherpa
    Location: Australia
  • Posts: 619
KLR650 Restoration....Please help......
« Reply #8 on: February 24, 2007, 04:26:43 pm »
I'm just off to bed, 0100 hrs here.
But I'll pop over to bikersa and have a gander at ya post.

Chains and sprockets are dead easy to replace (so long as none of the bolts or allen screws wear away when you're un-tightening them).

You may need a chain breaker and a master link.

Again I reckon a forum member probably has a chain breaker he could lend you.
You can also grind the chain plates away on a grinder. Watch ya fingers and eyes.

(And here the BMW GS owners all shout..." I've got shaft drive, don't need to deal with no dirty, oily, greasy chains!" ) :D

I agree it may be better to get a shop to do the fork seals, can be tricky if there are bolts to be undone in the lower fork legs.
(Al la BMW) :D

Let us know how ya go mate.

Cheers and good night/morning.
(Takin Lin trail biking tommorow, so up early for that.)
It's not just a mode of transport, it's a fking adventure!
 

bobnob

  • Guest
congrats
« Reply #9 on: February 24, 2007, 10:07:45 pm »
congrats on the bike!!!

with regards to the new disc i would say see if you can have it schemed

if the groves are not to bad a good enginering place will scheme it out nicely

otherwise have an enginering shop make you one (much cheeper) and spend the money you save on braded hoses front and back - apparently it makes a huge difference

i know exactly how you feel

my tt600 stops like a train with bicycle brakes - 2 drum brakes  :roll:
 

Offline Groenie

  • Forum Vendor
  • Moderator
  • Grey hound
  • ****
  • Bike: Honda CRF-1000L Africa Twin
    Location: Gauteng
  • Posts: 5,936
  • Thanked: 71 times
  • Ons gaan nou ry
KLR650 Restoration....Please help......
« Reply #10 on: February 25, 2007, 08:11:32 am »
Good news and congrats Captain. Sorry we missed each other when we were down there. You should do all the work or as much as possible, yourself. That way you get to know your bike and find all the other little things you missed on the first inspection. Remember Locktite is your KLR's best friend. The bike is a winner in the weight loss department, everything rattles loose after a few K's.

Check for a engineering shop in your area that can cut a new front disk for you. They wil charge you around R600 for it. The rest is easy, even the fork seals. You might have to fabricate a special tool to take the shock apart though, but being an engineering student, I'm sure you can weld?
Don't look back, that's not where you're going.
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #11 on: February 25, 2007, 12:41:51 pm »
What kind of Loctite should i use?

I'm going to see how much time i have and then do what i can.

Groenie, I agree with you i should do most of the work myself.
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #12 on: February 25, 2007, 12:48:08 pm »
I found two more items that needs replacement.

Front indecator housing.

What should i do to fix this cheaply? I was thinking of glue, but some of the pieces are missing.

Broken spoke on the rear rim.

A friend of mine was driving behind me when i fetched the bike and told me that the rear had a slight buckle, when i got home is saw one spoke is missing. Thats probably what caused the buckle. From my cycling years it wasn't that difficult to replace a spoke and straighten a rim. How difficult is it on a KLR? The wheels will have to come off for new tyre anyway.
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

Offline Jaqhama

  • Race Dog
  • ***
  • Bike: Kawasaki Super Sherpa
    Location: Australia
  • Posts: 619
KLR650 Restoration....Please help......
« Reply #13 on: February 25, 2007, 01:49:50 pm »
Front indicator housing...do you guys have bike wreckers in SA?

Many here. They normally have a whole boxload of indicator housings for most model bikes.

I was thinking you could get the discs from a wreckers actually.
Even the chain and sprockets if they are wrecking a complete bike and they are in ok condition.
It's not just a mode of transport, it's a fking adventure!
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #14 on: February 25, 2007, 01:59:41 pm »
Quote from: "Jaqhama"
Front indicator housing...do you guys have bike wreckers in SA?

Many here. They normally have a whole boxload of indicator housings for most model bikes.

I was thinking you could get the discs from a wreckers actually.
Even the chain and sprockets if they are wrecking a complete bike and they are in ok condition.


The parts that i ordered is still part of the original budget that i put out for repairs so thats fine.

I'll rather put new stuff on.

Jaq, you made me think again.  :D

I'm still going to buy new chains and sprockets, but i'm gonna store them till i really need them. I'm going to take off the old chain clean it properly and lube it again, refit and adjust. It should easily give me another 5000kms.
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

D7

  • Guest
KLR650 Restoration....Please help......
« Reply #15 on: February 25, 2007, 03:49:24 pm »
yo keptin

before shark goes on about the red ones being faster,  let me warn you.

it is nonsence.   the green ones are a tad quicker and a shirt load better looking!!!!!

on the up side - you got the right bike!!!!!!!!!!!!!!
may you have many  :D miles upon her

salut!
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #16 on: February 25, 2007, 04:01:10 pm »
Quote from: "D7"
yo keptin

before shark goes on about the red ones being faster,  let me warn you.

it is nonsence.   the green ones are a tad quicker and a shirt load better looking!!!!!

on the up side - you got the right bike!!!!!!!!!!!!!!
may you have many  :D miles upon her

salut!


I got 150km/h on the clock yesterday. :D
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin:
 

Offline KiLRoy

  • Kaptein Duiwel
  • Administrator
  • Gentleman Dog
  • ***
  • Bike: BMW R1200GS
    Location: Gauteng
  • Posts: 16,449
  • Thanked: 1266 times
  • Kaptein Duiwel - vriend van Beau Brummel
    • Wild Dog Adventure Riders
KLR650 Restoration....Please help......
« Reply #17 on: February 25, 2007, 11:41:54 pm »
Speak to Rooibaard in the shop section - he's breaking his KLR up for spares

H
 

Offline Watty

  • RIP 29-07-2011
  • Race Dog
  • ***
  • Bike: Suzuki Djebel 250XC
    Location: Eastern Cape
  • Posts: 3,954
KLR650 Restoration....Please help......
« Reply #18 on: February 26, 2007, 10:03:05 am »
Lots of info, maintenance tips, diagrams/photo's. FAQ, etc. available at these sites for the KLR650.  Especially the first two sites are invaluable reference sources for any KLR owner!  8)

1. KLR 650 FAQ
2. Kawasaki KLR 650 Forum
3. MarkNet - KLR650 : Doohickey Replacement (Idler Shaft Lever)
4. Conalls KLR650 Website

Enjoy!  :roll:
 

Offline El Zeffo

  • The white powder King
  • Gentleman Dog
  • *
  • Bike: Honda CRF-1000L Africa Twin
    Location: Western Cape
  • Posts: 16,159
  • Thanked: 580 times
  • Oudtshoorn / Mosselbaai
KLR650 Restoration....Please help......
« Reply #19 on: February 26, 2007, 12:35:05 pm »
Thanks for the info.

Greatly apreciated.  :D
I used to be called Captain Slow but then i got Zef
Most people say "Be like Elon" or "Be like Bill". I say "Be like Pablo" :biggrin: