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Old 07-24-2012, 06:02 AM   #3301
Maniac650
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Location: Central Washington
Oddometer: 28
09 models

Quote:
Originally Posted by Aprilia View Post
I actually prefer 08/09's as they have a reputation for oil consumption and wire harness rub throughs...makes for a cheaper price and I've twice proven I can get those years cheaper even after adding an oversize piston and going through the wire harness myself.

I have an 09 model and love it so far. Put 10k on it in 13months.... Killed one deer with it, and put it back on the
road more or less in the same condition it was.... (used to be Aztec red...now sports the 08 green motif)
The chain tensioner is loose now, but will get to that shortly.

To be honest with ya, I would really , really like to remodel this thing when the time comes, and put in a 650 twin, detuned, and exhausted correctly..... and change out the wire harness also. I love the size and functionality of this
frame. It fits me well, and drives ergonomically for me.... It just needs another 10-15 hp is all.

here is a link to a slideshow that I put together of the dry canyons we have here locally in Wa. ... and of KLR the 'red' lol''
http://youtu.be/LMUgCtDWNUE

I have more slideshows on that channel too. The last one seemed to run together and will be redone I suppose....

in short, the 09's are better than the 08's till you fix the ring problems...maybe the wireing harness rubs also.

-M
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Old 07-24-2012, 07:01 AM   #3302
Thumper26
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My problem is that I have a total of 3 bikes at the moment, two H-D Sportsters and a 1974 Honda CB-360. The budget is weak for bikes right now so I am wondering about the older (2007 and back) KLR 650's. I'd love to have a 2009 or newer, but that just isn't going to happen. Are there any early year KLR-650's that you guys could recommend, or specific years that I should avoid?

Any help would be much appreciated!

Thumper26
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Old 07-24-2012, 07:22 AM   #3303
XDragRacer
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Quote:
Originally Posted by Thumper26 View Post
Are there any early year KLR-650's that you guys could recommend, or specific years that I should avoid?
No.

The differences are, as Lewis Carroll said, famously quoted by George Wallace, the same as those between Tweedledum and Tweedledee (actually, cousins, not brothers/twins).

Thus, condition determines value; not vintage, IMHO. YMMV!
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Old 07-24-2012, 07:56 AM   #3304
Kawidad
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Quote:
Originally Posted by Thumper26 View Post
My problem is that I have a total of 3 bikes at the moment, two H-D Sportsters and a 1974 Honda CB-360. The budget is weak for bikes right now so I am wondering about the older (2007 and back) KLR 650's. I'd love to have a 2009 or newer, but that just isn't going to happen. Are there any early year KLR-650's that you guys could recommend, or specific years that I should avoid?

Any help would be much appreciated!

Thumper26
The earlier ones are just fine. The front brake and forks are not as good, but are just fine for the application and can easily be upgraded.
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Old 07-24-2012, 08:00 AM   #3305
Aprilia
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Quote:
Originally Posted by Thumper26 View Post
My problem is that I have a total of 3 bikes at the moment, two H-D Sportsters and a 1974 Honda CB-360. The budget is weak for bikes right now so I am wondering about the older (2007 and back) KLR 650's. I'd love to have a 2009 or newer, but that just isn't going to happen. Are there any early year KLR-650's that you guys could recommend, or specific years that I should avoid?

Any help would be much appreciated!

Thumper26
Up through 95 they were basically identical. 96 Kawa made some engine changes but otherwise identical up through 2007. Biggest changes were Bold New Graphics but even then those were recycled over the years.

I like my 92 with the older engine for the better gearing (internal) but like all these early engines the balancer sprockets should be upgraded to post 95 design. Otherwise same maint/cost things to look for throughout the entire 87-07 run.
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Old 07-24-2012, 08:14 AM   #3306
Thumper26
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Quote:
Originally Posted by Kawidad View Post
The earlier ones are just fine. The front brake and forks are not as good, but are just fine for the application and can easily be upgraded.
Thanks - good info.


Quote:
Originally Posted by Aprilia View Post
Up through 95 they were basically identical. 96 Kawa made some engine changes but otherwise identical up through 2007. Biggest changes were Bold New Graphics but even then those were recycled over the years.

I like my 92 with the older engine for the better gearing (internal) but like all these early engines the balancer sprockets should be upgraded to post 95 design. Otherwise same maint/cost things to look for throughout the entire 87-07 run.
Thanks much. Sounds like '96 on up would be the best to look for (re: post-'95 upgraded design). I am trying to plow through as much info as I can on the KLR-650 and hope to build my knowledge to the point wher I can help someone else "down the road" as much as you guys are helping me.

Thanks guys,

Thumper26

(by the way, my moniker is from the first bike I ever rode, which was the Panther - a 650cc thumper from England with compression release for starting. Talk about a THUMPER!)
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Old 07-24-2012, 09:13 AM   #3307
XDragRacer
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Wikipedia may add some granularity in response to your question, Thumper26:
Quote:
1987: Crankshaft is unique to this year.
1988: Beefed up the engine cases with extra bolts between the crank and countershaft; crank has a different part number, and may be lighter.
1990: Countershaft improved with longer splines for increased engagement with sprocket.
1992: Changes to front brake master cylinder.
Mid-1996: Changed valve cover, added bracket to hold cam chain bumper; changed crank to heavier unit; improved clutch basket with more clutch plates; changed countershaft sprocket retainer from slotted plate to large nut; changed second and third gear ratios. Kickstarter no longer fits with new clutch basket. At least some early 1996 models had the matte black engine cases and covers rather than the later hammer-finished dark gray coloration found in the 1997 and later models. New left balancer weight/sprocket begins with engine #KLE650AE032206.
(?) Service manual indicates higher charging system output; only part number change is the rotor. The new power rating is 17 A, 14 V (238 W) @ 7000 rpm; the earlier one was 14 A, 14 V (196 W) @ 8000 rpm (above redline).
2001 around this time final assembly moved from Japan to Thailand. All major parts still made in Japan.
2007: New shift lever
What? Design essentially static for 20 years?

Yes.

None of these yearly changes would be a deal-breaker for me, in light of condition, but . . . YMMV!
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Old 07-24-2012, 10:19 AM   #3308
mxboy96
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Quote:
Originally Posted by RevBill View Post
.. okay .. it just me or does this thing look like a big Mt. Dew???
I think it looks wicked myself;) I shouldnt have been in such a hurry and held out for a 13 model
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Old 07-24-2012, 10:29 AM   #3309
Tsotsie
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"The new power rating is 17 A, 14 V (238 W) @ 7000 rpm; the earlier one was 14 A, 14 V (196 W) @ 8000 rpm (above redline)."

I think Wiki got this wrong or the Wiki writer did not edit properly

07- , has a 14A alternator
08+, have a 17A alternator . This to compensate for the dual headlights at 55w ea.
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Old 07-24-2012, 11:39 AM   #3310
XDragRacer
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Quote:
Originally Posted by Tsotsie View Post
"The new power rating is 17 A, 14 V (238 W) @ 7000 rpm; the earlier one was 14 A, 14 V (196 W) @ 8000 rpm (above redline)."

I think Wiki got this wrong or the Wiki writer did not edit properly

07- , has a 14A alternator
08+, have a 17A alternator . This to compensate for the dual headlights at 55w ea.
I think you're correct, Tsotsie; the question mark on the date for this entry should be, "2008," IMHO.

Anyone have Generation 1 and Generation 2 Service Manuals for confirmation?
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Old 07-24-2012, 12:46 PM   #3311
Tsotsie
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Quote:
Originally Posted by XDragRacer View Post
Anyone have Generation 1 and Generation 2 Service Manuals for confirmation?
Yes, the 08 edition of the Factory Service Manual has it as is 17 A.
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Old 07-24-2012, 01:11 PM   #3312
XpressCS
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So us earlier generation KLR owners have 14 amps to work with... Realistically about 10 tops, to charge the battery.

Perfect for what I want to do. Wonder what the bike would look like with twin Dominator headlights?

http://www.flyncycle.com/Dominator_T...p/hlutrblk.htm
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Old 07-24-2012, 01:28 PM   #3313
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96 and newer would be a better choice if you think you may want to do a 685 or 705. When I converted my 95 bike to 705, I had to buy a new cylinder.
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Old 07-24-2012, 01:39 PM   #3314
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Quote:
Originally Posted by XDragRacer View Post
Anyone have Generation 1 and Generation 2 Service Manuals for confirmation?

I have a first gen service manual. It covers KL650 A1-A9 models (I believe this is 1987-1995, right?) and has the output listed as 14A @ 8000RPM.

However, there are two chapters at the end of my book, one is the "2000-2001 Supplement (KL650-A14/A15)" and the other is the "2002 Supplement (KL650-A16)." Both of these years are listed as 17A @ 7000RPM

This leads me to believe that sometime between 1996 and 2000, the stator was changed to a higher output unit.
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Old 07-24-2012, 05:10 PM   #3315
Tsotsie
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Quote:
Originally Posted by sandalscout View Post
I have a first gen service manual. It covers KL650 A1-A9 models (I believe this is 1987-1995, right?) and has the output listed as 14A @ 8000RPM.

However, there are two chapters at the end of my book, one is the "2000-2001 Supplement (KL650-A14/A15)" and the other is the "2002 Supplement (KL650-A16)." Both of these years are listed as 17A @ 7000RPM

This leads me to believe that sometime between 1996 and 2000, the stator was changed to a higher output unit.

KAWA are notorious for textual mistakes. (6th gear etc).

I have, in addition to the 08 factory manual at 17A , a 1987-2003 Clymer manual. It lists those models range as 14A.

I recall at the launch of the 08 the publicity listing the alternator change to 17A as one of the up- grades. The reason given was the change from a single H4 headlight bulb of 55 low, 65w high or 65 w max on high beam, of the up to 07 model to the dual bulb 55w low plus the 55w high beam headlight system or 110w total on high beam for the 08+. The P#'s and the rectifiers are different from 08 too.

I run a 35w HID low beam on the 08 as well LED's in the tail and tag lights. I guess then that I have about 25 w or 2A extra to play with. Not using the high beam means that I have a full 80w free over what the battery needs to charge itself. I run a 70w Gerbings in winter. Dont really need high beam with the HID. Those tied to an Odyssey battery has resulted in a completely trouble free electrical system for 4 years now
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