Many suppliers are experiencing HUGE increases in demand and supply chain delays. We appreciate your patience. The quickest way to get your item is to place your order now which guarantees your place in line.
The Kawasaki KLR650 is a 651 cc single, liquid-cooled, 4-stroke, DOHC, 4-valves, dual-sport motorcycle intended for both on-road and off-road riding. It was a long-standing model in Kawasaki's lineup, having been introduced in 1987 and remaining almost unchanged through the 2007 model. The 2008 model was the first significant redesign of the KLR650 since its inception.
| Chain Size: | Front Sprocket: | Rear Sprocket: | Front Tire: | Rear Tire: | Spark Plug: |
| 520x106 | 15T | 43T | 90/90-21 | 130/80-17 | DP8EA-9 |
All the advantages of a flatslide pumper carburetor at a much friendlier price than a Keihin FCR. Our complete Mikuni TM40 pumper carburetor kit comes with alloy adapter rings bonded to the carburetor body for a firm reliable fit in the stock air boots. We also include a remote mounted choke knob, complete instructions along with a wide range of main jets and pilot jets for fine tuning or to accommodate bikes with extensive modifications.
2022 marks ProCycle's 20 Year anniversary. This limited edition T-shirt commemorates this grand accomplishment with our favorite local riding area as a topo map perfectly placed on the back and a 20 year stamp on the front.
Available for a limited size run in olive green 100% cotton.
Finally! Quality replacement body parts at a fraction (35%!) of the OEM parts. Polisport's parts have been developed with their exclusive technologies - IPD (In-mold Plastic Decals) and DGP (Durable Gloss Propylene). These processes make these parts even more resistant and durable than the stock units with a perfect fit and glossy finish. The Side Panels include heat protection film, washers and rubber grommets, just like the OEM parts.
You can purchase individual parts, or a discounted complete kit. If your taillight unit was damaged with your rear fender, we offer a brand new OEM unit as an optional add on.
The Moab Pro-Series shock from Cogent Dynamics is the standard by which all other shocks are judged in the KLR world. With its superior performance and exceptional reliability, Moab Pro-Series shocks have literally conquered the world many times over. The staff at Cogent is as passionate about motorcycles as you are.
Spring duties are handled by a custom spring available in either Standard or Heavy-Duty weights. The Standard spring will be fine if you are under 250 pounds and don't ride with luggage or passengers often. If you regularly carry luggage boxes and/or a passenger and weigh over 250 pounds, you will probably prefer the Heavy-Duty spring. Call if you have any questions.
Because of the limited space with the reservoir, adjusting your preload is just about impossible and for that reason we only sell these units with the Cogent Hydraulic Preload Adjuster already installed!
For a true comfort and performance package, we highly recommend upgrading your front suspension at the same time.
Shocks are Custom built to order: Please allow 2-3 weeks for delivery
If you have '87-'07 KLR, you MUST order new mounting bolt. Not required for 2008-2018 models.
Not sure what to get the adventure/ dualsport rider in your life?
How about a ProCycle Gift Card!
Load as much as you would like in $25 increments. This is a digital gift card, we will send you the information and redemption code via email once the order is processed.
*please allow 1-2 business days after the order is placed to receive the email containing the details and redemption code.
Your automatic cam chain tensioner is spring loaded. This can make it difficult to install as it wants to extend before you have it bolted into place. This handy tool will back off the cam chain tensioner mechanism and hold it for you. No more awkward 3-handed contortions are required to get the tensioner installed.
A pair of stage 2 intake and exhaust 'drop-in' camshafts. Great mid-range and top-end increase. Uses stock valve springs. Modifying the airbox and rejetting will be required to realize power improvements with these cams. These are new billet cams - No core return required!
29mm diameter - Includes two valve shims of each size 2.30, 2.40, 2.50, 2.55, 2.60, 2.70, 2.80, 2.90, 3.00 and 3.10. 20 shims in total. From K&L.
For adjusting valve clearance on twin cam models. Holds valve spring collar down so adjusting pads can be removed. From Motion Pro, made from hardened alloy steel.
Higher pressure in the cooling system, raises the coolant boiling point and increases protection from coolant loss due to overheating.
23 PSI - 1.6 Bar.
A direct replacement for the stock KLR hoses that tend to crack and leak after a few years.
These silicone hoses are custom made for us. Silicon hoses operate at much higher temperatures and pressures than other rubbers, they don't perish, and they look great!
Our very own version of the popular thermostat bypass for the KLR. Gives faster warm up and more constant engine temperatures. Eliminates the wildly fluctuating engine temperature gauge. A more controlled and constant temperature is easier on your piston and cylinder and may prevent or reduce oil consumption. We use a 180 degree thermostat instead of the stock (too cold!) 160 degree unit. Warmer coolant temperature promotes better fuel vaporization and can increase fuel economy.
Our bypass system mounts the new thermostat in a small billet extension housing right where the stock thermostat is now. There is no bulky external housing to hang off the motor. The bypass hose tees in to the lower radiator hose using a length of quality high temperature silicone hose. It all makes for a clean simple installation.
The complete Thermo Control package - Our in-house designed Thermostat Bypass kit, a set of Custom Silicone Hoses and a Hi-Pressure Radiator Cap. All combined to help your KLR cooling system be at the top of its game. The Thermostat Bypass kit includes a thermostat with a higher temperature rating that will keep the motor more in its happy spot.
The Silicone hoses are stronger than the stock rubber units and will better resist cracking and leaking.
Complete Doohickey Replacement Kit now includes the outside cover gasket. Complete kit includes:
The genuine Eagle Manufacturing balancer lever kit. All top quality components.
A high quality torsion spring puts more consistent force on the tensioner lever. Requires drilling a small hole in the case to seat the spring. Drill bit included.
Special tool to remove the flywheel/rotor from the end of the crankshaft. You have to remove the flywheel/rotor to upgrade the doohickey.
You have to pull the rotor off the crank of your KLR to access the doohickey. The offset in this factory Kawasaki wrench makes that very easy. It is very difficult to get a standard wrench to hold the crank to get the flywheel/rotor off.
Complete set of friction plates, HD springs and steel separator plates prevent premature driven plate wear, oil muddying and loss of stack height. Built with swaged aluminum carriers that spread the load on the clutch basket and prevent clutch basket "dogging". Anti-swell, alloy impregnated heavy-duty cork-based facings for smooth clutch take-up. Allows modulation, unlike paper clutches which tend to snatch.
The Rekluse EXP employs the same EXP assembly as their premier product; the difference is that it fits into your stock clutch assembly, saving you money! Now you can enjoy the benefits of Rekluse auto-clutch technology on your KLR.
An auto-clutch automatically feeds out the engagement of the clutch using centrifugal force. This allows you to start and stop without touching the clutch lever. The automatic feed is fully adjustable to suit the rider's needs while retaining full manual override with the clutch lever. This automatic feed delivers easier on/off throttle transitions, improved traction, better control, and more confidence.
Replacing your clutch or removing that side cover for any reason? You are going to need a new gasket for the cover to ensure a leak-free assembly.
Generator cover gasket to seal up the cover once you have your new Doohickey in place. New OEM gasket. What else can we say? If in doubt, put in a new one.
Put fresh O-rings on your KLR when you do your next oil change. Here you have new ones for the Oil Filler and the Oil Filter Housing Cover.
Superior Filtration:
This should be the last oil filter you will ever buy. Made from laser cut, medical grade, 304 stainless steel micronic filter cloth, this filter provides 200% more filter area in many cases. Most good paper filters will pass particles in the 90 to 95 micron range, and some tested, as much as 300 microns. Sand is about 125 microns and a white blood cell approximately 25 microns. Flo's stainless filter catches items down to 35 microns "absolute", which is about 3 times better than most good paper or brass filters. The pleat seam is welded, able to withstand up to 600 degrees in our filter, not glued, like paper filters.
Providing unbeatable performance and exceptional value, Hiflofiltro is the best-selling brand of aftermarket filters for motorcycles, scooters, and ATVs worldwide. The filters are also supplied to original equipment manufacturers as well as private label brands.
You pay $3.00 per filter with our value 10-pack!
A 10-pack of drain plug sealing crush washers. Replace your sealing washer at every oil change to prevent a leak.
Stock and typical after market drain plugs can protrude past some skid plates. This steel low profile drain plug stays inside the skid plate so it can't be snagged by passing objects.
Comes with 4 crush washers.
Extra protection for your motor! Strong magnet at the end of the plug picks up metallic flakes in your oil, protecting your engine!
GoldPlug is the gold standard in engine protection.
Stainless steel drain plug with an extremely strong magnet that picks up metal flakes in your oil.
12mm Thread, 17mm Head.
Hardened chrome vanadium steel with built in rubber insert to hold spark plug steady.
Thin wall bi-hex sockets designed to access narrow spark plug holes.
Fits 3/8" square drive and hex drive, 16mm, 18mm, 21mm.
E3 Resistor Spark Plugs
Iridium spark plugs are made with premium quality materials.
Iridium plugs last longer than standard ones, meaning you won't have to replace them as often.
Sold individually, unless otherwise stated.
Keep your motor running right with fresh spark plugs!
NGK is one of the world's largest manufacturer of spark plugs, whose products are used as original equipment (OE) on countless motorcycle and automobile models.
Clymer repair manuals provides step-by-step procedures based upon the complete disassembly of the motorcycle. This hands-on experience combined with extensive research results in a manual that is both user-friendly and detailed. Contains hundreds of original photos, exploded views, drawings, specifications and charts to illustrate each job. Also features shortcut repairs and high-performance modifications.
Whether you're interested in routine maintenance tasks, troubleshooting, or more extensive repairs, the in-depth coverage provides indispensable information about your KLR650.
Includes degree wheel, dial-gauge, multi-position stand, extension, 3-sizes of positive-piston stops, and a handsome wooden carrying case.
Made from medium carbon steel with hardened jaws. It features spanner pins and the jaws open up to 5" wide. It's ideal for holding clutch hubs, flywheels, gears, sprockets, etc. Made by Motion Pro.
This tool is designed to separate vertically split crank case halves on two and four stroke engines. Adjustable arms allow it to be used on multiple bolt patterns found on a variety of makes and models of motorcycles. Industrial grade steel construction with black oxide finish for long service life. Comes with 8mm mounting bolts and 6mm adapters. Protective carrying case included.
For easy removal of recessed oil filters.
Conical point screws pierces and grabs the metal end cap of the filter.
reduces potential damage to the engine cases.
NOT for use on re-usable oil filters.
A 3-pack of easy to apply strips measure the temperature of engine, suspension, and radiator components. Temperature range 146° to 248°
Thread Chasers are designed to clean and re-cut damaged aluminum threads.
this kit contains the two sizes most common on metric motorcycles, M6x1.0 and M8x1.25.
Thread Chasers also remove dirt and metal shavings that become captured in thread grooves.
Uses 8mm or 10mm hex sockets, a Must for all tool kits.
Dual marked feeler gauges. 32 blades from .03mm/.001" to 1mm/.040"
All the advantages of a flatslide pumper carburetor at a much friendlier price than a Keihin FCR. Our complete Mikuni TM40 pumper carburetor kit comes with alloy adapter rings bonded to the carburetor body for a firm reliable fit in the stock air boots. We also include a remote mounted choke knob, complete instructions along with a wide range of main jets and pilot jets for fine tuning or to accommodate bikes with extensive modifications.
Designed for use with stock engines using either stock or aftermarket exhaust and air filters.
The new FMF Power-Up jet kit makes jetting your carb simple. They've teamed up with DynoJet to produce a kit that offers you a selection of jets and/or needles to get maximum horsepower out of your KLR. The easy to use instructions have diagrams and step-by-step procedures to help you get your jetting where it needs to be, no matter what elevation you ride at. No more driving back and forth to the dealer with a handful of jets and needles with a million questions running around in your head about where to start or turn next.
This kit includes 2 Needles that have been developed by JD Jetting and manufactured for them to their exacting specifications. These two needles allow a wide range of tuning possibilities and provide correct fuel delivery at any throttle position.
4 allen type screws for the float bowl are also enclosed should you strip out the stock screws during your tuning process. Complete instructions with photos, jetting suggestions for different set-ups and situations, 5 Main Jets and a drill bit complete the package.
Comes with everything you need to freshen up your carburetor.
Has your TM carburetor been sitting for too long and now needs to be rebuilt? Then what you need is this TM40 Rebuild Kit that contains Genuine Mikuni replacement parts.
This kit includes:
Softer return spring for your TM40 carburetor.
This replaces the stock return spring that comes with the TM40 carburetor creating a 25% lighter throttle feel.
Strip out the bowl screws on your KLR? Carb top screws get rusty? Here is a set of 4 allen screws and lock washers for the bowl and 4 allens and flat washers for the vacuum top.
Replacement socket head (Allen) screws in case you strip out the stock JIS heads on your TM40 bowl. The originals can be stripped out when doing any tuning or carburetor maintenance. Sold in a pack of four, all for the bowl.
Have you lost or broken the stock air filter cage for your KLR? Maybe you need a spare? Here it is, the OEM cage that will fit any of the foam air filters on this page. This kit includes the cage and the mounting hardware.
Dual stage foam: 2 different pore sizes create more trapping area for even the smallest dust particles. Flame laminated foam: Both "Stages" are not glued but heat sealed to provide maximum air flow. Light color foam makes it easier to see where the filter oil has covered and where it has not.
Twin Air's patented design, high quality materials and superior construction deliver unbeatable performance and protection - and make Twin Air Filters the hands-down choice of more World and National Champions than all other filters combined.
An air filter is your engine's only protection against the elements, and your stock filter isn't up to the task. Replace it with a Twin Air - the #1 filter system proven on motocross tracks around the world.
Twin Air's fused layers of open-pore foam and fine inner foam trap even the smallest particles-without restricting airflow.
Sold in 6 packs
This canister by Pro Circuit allows you to move the overflow tubes from the carburetor up and out of the way. Universal application.
Quick release one-piece clamps that saves space. These are great for fuel lines, controlling wires, and can be used many times.
Comes with 4 each of 8mm, 9mm 10mm, and 12mm.
No special tools needed, from Helix Racing.
6.6 gallons just not enough? Here is your answer, the 10 gallon tank from IMS. This tank is so large that they installed an internal lift pump to use the full capacity of the tank while maintaining a lower center of gravity than the OEM tank.
Can use factory locking cap or IMS screw on cap. Wing Tank - Does Not Use OEM/Stock Shrouds
Get better range from your early KLR650 by adding an IMS 6.6 gallon fuel tank. The big tank also provides radiator protection.
Designed to enhance the appearance of your motorcycle, yet provide greater riding distance per tankful. Larger capacity than stock, yet very slim and sleek. Perfect for the dunes or the race track! These tanks are made with POLYETHYLENE CROSSLINK for extra strength and durability.
Natural color is recommended if you wish to easily see the fuel level in the tank.
This tank requires you to re-use your stock petcock valve. Does Not Use OEM/Stock Shrouds
These great grip pads give you that improved relationship between you and your machine. You will feel the difference the minute you throw your leg over. Squeeze your tank and feel what a solid seat position is and does for you. They will assist in reduction of vibration, increase in control, and increase in comfort.
Will also help you cover wear spots on your tank whether it be the stock metal or a plastic tank. We tested had a couple sets of these on bikes with plastic tanks for at least 3 years and saw no signs of bubbling, peeling or coming off in any way.
If you're like us, you hate the long floppy vent hose hanging off the cap of your aftermarket tank. This one-way vent cap replaces the long hose with a short one only about 2" long. It allows air into your tank but prevents fuel from sloshing out. Machined from billet alloy and anodized for good looks.
Not for stock fuel tanks!
Security for your fuel tank. Includes 2 keys. Internally vented with a check valve that prevents spillage in case of a tip over.
Fits Acerbis, IMS and safari tanks only.
A replacement gas cap for your IMS tank. Newly redesigned to resist damage from new fuel additives that were hard on the seal in the old style cap.
Does your stock vacuum operated petcock not shut off when your bike is parked? Replace your stock vacuum operated petcock with this manual one. Must be shut off any time the bike is parked for more than a few hours. Fits stock or aftermarket tanks. Plastic tanks may need the hole 'ovalized' to fit the dual standpipes.
Does not fit OEM XR650L metal tank
The small size and right angle hose barbs make this filter easier to fit into the small space between your fuel petcock and carburetor. Filter body is only 7/8" diameter. Straight filter is 2" long, 90 degree filter is only 1-5/8" long.
This filter is meant for 5/16" fuel lines. Only 1/2" thick it is small enough to fit just about anywhere.
Fuel supplies can be sketchy at times. This filter lives in your tank to trap dirt and debris as it is poured into the tank. Features a custom shaped adapter that fits securely under the gas cap, creating a leak-proof seal. If it stays out of your fuel, it can't get into the carburetor! Created by the filter experts at Twin Air, this filter fits IMS, Acerbis and Safari brand gas tanks.
Ordering new fuel line? How about a set of fresh zinc plated clamps to go with it?
These will be sure your fuel line stays connected. A pack of 8 clamps in 2 sizes to fit most 1/4 or 5/16 fuel hose.
Hose reducer to go from 5/16" line down to 1/4" line. Many bikes have 5/16" carburetor spigots but most aftermarket petcocks are 1/4". This solve the problem of mismatched sizes. Solid brass construction. Can be used to route or repair fuel lines, oil lines or air lines. Barbed ends provide a secure fit.
30" lengths. Sizes shown are ID. All of these lines are stronger and more durable than vinyl fuel lines and are resistant to swelling, UV light, as well as hardening and cracking.
Need to mount two containers? A water and a fuel? Two waters? Already have a RotoPax Mount for a single container? Get this extender to work in conjunction with a pack mount and that will be no problem! Single mount, two containers.
RotoPax holder made to mount a single Fuel and/or Water container.
Need to mount two containers? A water and a fuel? Two waters? Get the extender which allows you to stack two containers no problem! Single mount, two containers
RotoPax holder made to mount a single Fuel and/or Water container.
This unique design adds strength and provides extra tightening power.
Use with included base plate or remove plate to attach mount direct by bolting up through the bottom or down through the top.
RotoPax are Rotational Molded - the process which produces indisputably superior products.
Need to mount two containers? A water and a fuel? Two waters? Finally, you can stack multiple packs together! Use in conjunction with a pack mount. You will need to purchase the Single Mount as well as the Extender.
Auxiliary fuel tanks mount to handlebars, forks, or rear racks.
This Super Siphon has a (1/2 inch x 6 foot) long hose, which makes it quite easy to transfer fuel from one bike to another! Simply, shake the hose to prime it and get fuel moving. The hose is resistant to gasoline and any other hazardous chemicals. Roll it up, stuff it in your bag and you will be very happy whenever you need it.
This product is a windscreen lip that will offer more protection from the wind and weather. These mount directly onto your existing windscreen.
Standard Lip for stock windscreen.
AVAILABLE IN CLEAR ONLY!
The Bajaworx Dakar Clear windshield for the KLR650 is designed to direct the wind over even the tallest of riders without compromising visibility. Decreased wind noise, reduced buffeting and more control in strong crosswinds make this a fantastic addition to your newer KLR.
Windscreen attaches to your bike's handlebars. Fully adjustable mounting brackets. Includes 7/8' handlebar clamps. 14" tall & 10" wide.
Will not fit 1 1/8" oversize handlebars.
The Rally windscreen from Parabellum is the perfect protection from wind and debris without sacrificing technical off-road capabilities. This is an upright rally type windscreen that looks aggressive and performs well under all types of riding. Designed primarily for the off-road / dualsport enthusiast, this shield keeps pressure off the rider's chest while commuting from home to adventure and back.
This windscreen mounts securely to the three stock windshield holes as well as the two side cowling mounts. The shield is 14 inches tall, 13 inches wide at the bottom narrowing to 11 inches at the top. Made from 3/16" military aircraft grade cast acrylic.
The long over-due rally shield for the 2008-on KLR650 is finally here!
Parabellum uses 4 steel brackets mounted to factory locations as well as our stand-off windshield design to ensure the customer doesn’t have to drill extra holes in the cowling but still achieves that iconic upright look of the real Dakar Rally bikes.
The Rally shield protects the rider’s torso/chest from air, cold, roost, branches and bushes while leaving the rider’s head/helmet in clean air. We recommend the Rally shield for riders seeking some protection, but prefer to be off-road.
The Rally shield is made from 1/8 inch cast acrylic and is 11.5 inches wide at the bottom and 17 inches tall.
The Replacement windshield from Parabellum has been designed, developed and tested using all the knowledge and experience of the KLR riders in their own shop. Using the stock mounting points as well as the cowling mounts increases the rigidity of the shield. All new fasteners are included. This new design allows you to move your handlebar to different positions and will not interfere with a stand-up position for off-road use.
This shield is constructed of 3/16" military grade cast acrylic that is 17 inches wide at the bottom tapering to 16 inches at the top.
The new Touring windshield for the 2008-on Kawasaki KLR650 has been completely redesigned to both improve protection as well as appearance.
Parabellum utilizes the stock windshield screw locations with our angled brackets to mount the newly designed shield. The windshield uses stand-off technology so the shield is more upright. This allows a smaller shield to give more protection. This also keeps the top edge of the shield away from the rider when standing on the pegs and using other off-road riding techniques.
The Parabellum Touring shield for the KLR is also significantly wider and taller than the factory windshield maximizing comfort and wind protection.
The windshield measures 14.5 inches wide and is available in two heights. We recommend this windshield for those seeking maximum protection. The shield is made of 1/8 inch cast acrylic and offered in clear or tint.
Puig Visor Clip-On
Zero Gravity windscreens feature the finest optics of any windscreen on the market. All Zero Gravity windscreens are fabricated using highly specialized "vacuum forming" techniques similar to those used to form aircraft canopies. The result is a virtually distortion free optical lens.
Made from the finest grade of acrylic plastic, Zero Gravity windscreens are stretched as they are formed, a process which results in superior strength and flexibility. This flexibility allows the windscreen to absorb road vibrations and resist cracking. All of our windscreens are factory pre-drilled and ready to install. The mounting holes and windscreen profile match the O.E.M. windscreen for a precision fit.
Zero Gravity currently offers three types of windscreens for the new version of the KLR.
SR is the Stock Replacement
DB is the Double Bubble screen
ST is the Sport Touring model.
The DB model is approximately 1.75 inches taller than stock and the ST is approximately 3.5 inches taller than the original. Each screen is available in Clear, Smoke or Dark Smoke colors as well.
Quality replacement radiator air scoops. Sold in pairs for gen 1 KLR650.
Available in 4 colors.
Finally! Quality replacement body parts at a fraction (35%!) of the OEM parts. Polisport's parts have been developed with their exclusive technologies - IPD (In-mold Plastic Decals) and DGP (Durable Gloss Propylene). These processes make these parts even more resistant and durable than the stock units with a perfect fit and glossy finish. The Side Panels include heat protection film, washers and rubber grommets, just like the OEM parts.
You can purchase individual parts, or a discounted complete kit. If your taillight unit was damaged with your rear fender, we offer a brand new OEM unit as an optional add on.
Replacement front fender by Maier that will fit great on your Kawasaki.
Available in 4 colors.
Universal design. Vents in the back improve airflow to motor. Smaller front reduces 'wind steer' and improves high speed stability.
Universal off-road front fender. Must be drilled to fit your mounting bolt pattern.
Quality replacement headlight fairing for Gen 1 KLR650.
Available in 4 colors.
New replacement rear fender for the Gen 1 KLR650.
Available in 4 colors.
New replacement side panels specifically made for gen 1 KLR650.
Available in 4 colors.
Will not fit KLR250
This frame includes six, white, full-spectrum LED bulbs on a 6-inch strip for bright illumination of your license plate. It is made in a sturdy cast aluminum, and is powder coated with a durable black finish.
Outside frame dimensions are 7.25" in. wide by 4.2". Center to center mounting hole distance is 5.7 in. All mounting hardware is included.
This is the brace needed to stabilize the wing like structure they call a front fender on the KLR – both generations. This simple bolt-on reduces wind buffeting and increases steering stability at highway speeds. It also helps carry the weight of a fender mounted tool bag.
Made from laser cut 5052 aluminum, then CNC formed and beautified with a shiny black powder coat. Easily mounts in a few minutes using the included stainless steel hardware.
Adhesive heat shield for your new side panel plastics to protect it from the heat of your muffler.
