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(Click here
to skip this section and go straight to the Table of Contents)
Introduction
Basic maintenance is unfortunately often neglected
by many KLR owners even though it is described in the owner's manual.
Maybe it is because some people simply just don't read the manual or they think
it was done during the last service. (Very few shops do routine maintenance) If you don't
want to take care of this yourself, then at the very least pay the shop to do
it. This is important, as the many times we have seen broken down motorcycles on the side of the road.
The failure can sometimes be
directly attributed to a simple case of neglected basic maintenance. (In
some cases the owner has spent hundreds of dollars on useless accessories, yet
didn't think twice about basic maintenance ) Cables and chains simple don't break without
warning. Often
it is the result of accelerated wear due to lack of lubrication or maintenance.
Also sometimes just the
simple act of checking some of the more common fasteners may prevent grief at the trail side.
(See known
issues) In addition, Elden has written up an extensive article about Chains
that every rider should read before venturing out on a long trip (See Article)
Another concern
is loose spokes which can result in poor handling and seems to be a common
problem on the KLR650. However, this is not only a problem with the KLR650 but
other manufactures as well. In fact, one of our local favorite wheel builders claims
in some cases the spokes can actually come improperly torqued from the factory
and much of
his business is just properly tuning wheels on brand new bikes.
CONTENTS
The
entire procedure is broken up into several sections that include some optional
upgrades or conversions. Due to the size of this procedure, we have
included the following short cuts to each of the sections. This will help the
reader quickly navigate to sections they are interested in.
(Click
on the section that you are interested in)
Chain
Adjustment
and Upgrades
Clutch Cable Lube and Adjustment
Throttle Cable Lube and Adjustment
Speedometer Cable Lube
Air Filter Service
Battery Care
Tires
The Once Over
The most
important thing to remember in this section is to simply read your owners manual and
go with the recommended intervals!
What you will need:
Tools
Basic metric tool kit
Ruler or tape measure in mm's
22mm & 24mm Sockets
Adjustable torque wrench that goes up to 72 ft lbs
Grunge Brush
Twin Air Cleaning Tub
or equivalent (Twin Air P/N
159011)
Upgrade Parts
8mm nut (Kawasaki P/N 92015-1658)
8mm lock washer (hardware store)
Maintenance Free Battery Yuasa® YTX14AHL-BS (optional)
UNI® Air Filter P/N NU-2378ST
(optional)
Consumables
Blue or medium strength Loctite
Kerosene or Stoddard
Solvent
Alisyn chain lube
Cable life lube and injector
Maxima FFT® foam filter oil
Light weight Molybdenum Disulfide grease such
as:
Stay lube engine assembly grease
w/moly (NLGI
0-½)
Schaeffer
#238 Moly Ultra Supreme (NLGI 1 or 2)
or Ford Speedometer cable lube (Ford P/N B5A-19581-A)
Low lint rags/towels
Nitrile Gloves
25% baking soda solution or PERMATEX®
Battery Cleaner
Vaseline® or PERMATEX®
Battery Protector
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