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  #1  
Old 31 Mar 2008
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Hey Pockethead,
Do you have a KLR? I just read your website about motorcycling to south america, when do you plan on heading out?
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Old 1 Apr 2008
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Originally Posted by cruthas View Post
Hey Pockethead,
Do you have a KLR? I just read your website about motorcycling to south america, when do you plan on heading out?
Hi Cruthas,
I don't own a KLR just yet, planning to buy one upon arrival in the states, which will be sometime after October this year
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Old 1 Apr 2008
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KLR maintenance
To save a few bucks when doing valve clearance adjusts go besides Kawasaki, to Yamaha,Suzuki and Honda dealers. All these brands have or had models which use the same diameter valve shims , sized in the same thickness increments. There are also probably automobiles which use similar shims , and all are perfactly good to interchange. You may be able to buy the sizes you need from their stock of used exchanged shims at a consederable discount. Also before trading or buying new be sure the shim you remove from one location is or is not a possible fit for another valve in your motor.
Check valve clearance at about 15000km intervals, but you may not even need adjusts.
To change shims as per shop manual you need to remove the cams. But I have heard there is a way or tool which lets you leave them in.
If you do remove cams do STUFF A RAG in the camchain tunnel because one of the bolts holding the oil splash deflctor is real short and has a tendency to get dropped. No fun spending an hour or two fishing it out with a magnet. Done it.
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Old 1 Apr 2008
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I allways change the oils in any secondhand bike I get. When I get it - ... start that the front and work to the back - fork oil, coolant, engine oil .. etc. Look at the oil that comes out .. it will sy a lot about the bikes history.

If your going on a longer trip - have the rear shock serviced, they don't have much oil in there and it does a lot of work (serviceing will tell you if it is near worn out).

The doohicky? No tell tail sign I know of. It just fails. Should be some stuff on advrider .. with picys on doing the doohicky. Should be easy to look inside for it.
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Old 1 Apr 2008
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Thanks for the information, the bike seems to be in good shape, I am going to go ahead and try and replace the doo-hickey even if it isnt broke, and see if the valves do need to be adjusted. What is the difference between the stock KLR front shocks and progressive shocks?
Pockethead,
I will be doing the same trip you are around the same time you arrive in the states, where are you flying into? Do you have family or friends here? I would be interested in traveling, do you have a time frame of when you are leaving?
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Old 1 Apr 2008
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Originally Posted by cruthas View Post
Thanks for the information, the bike seems to be in good shape, I am going to go ahead and try and replace the doo-hickey even if it isnt broke, and see if the valves do need to be adjusted. What is the difference between the stock KLR front shocks and progressive shocks?
Pockethead,
I will be doing the same trip you are around the same time you arrive in the states, where are you flying into? Do you have family or friends here? I would be interested in traveling, do you have a time frame of when you are leaving?
Excellent, so far my plan is not set in stone but to fly into California either San Fransisco or Los Angeles ideally in October (then ride to the 'Vegoose' rock festival in Las Vegas, 2 days camping there) but I think it will be a pretty tough deadline to make, most likely I will arrive in December (however I'm working on a couple of side projects to make extra $$ outside of work, if they are successful October will be easy). From there with no family or friends in the states maybe stay at a backpackers or several people here have offered some temporary accommodation (very thankful), I estimate 2-3 weeks to obtain a bike, title and insurance then I plan to get to Mexico as soon as possible and from there just head south


I'd be glad to meet you if you are on a similar route, give me a bell if you're interested we'll arrange something.

Also, checking the valve clearances is a very big job, make sure you have a Clymer manual if you're not too mechanically apt (like myself):
CLYMER Repair Manual- KLR650.com

you'll need a lot of garage space too and having a friend around will help.
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Old 1 Apr 2008
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Do the Doo
I own 2 KLR's a 2001 and a 2005. It is important to replace the doohickey on the 1995 model unless it has already been done. You won't know this until after you have opened it up.

Buy one of the after market doohickeys and not another Kaweasaki model.

There are a few sites if you google that have step by step instructions complete with pictures that will be of great help.

Buy some blue locktight before reassembly as this will save you from looking in the dirt for the missing nuts, bolts and screws later. As a matter of fact it has been suggested and I agree that you should take a tube of blue locktight and get familiar with every screw and nut you can get your hands on.

Have fun.

Rick
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