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KLR650: Engine

KLR650

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

 

Engine

KLR650 '85 - '18

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.

Ships in 3-5 business days
$99.95

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!

Ships in 3-5 business days
$399.95
KLR650 '87 - '18

K&L® shims exceed the maximum of the Apparent Rockwell Hardness "C" scale. Shims average 47.0 compared to the 46.0 maximum.

This kit fits KLR650 87-18 as well as other brands and models , please verify correct size for your model before purchase.

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.  In a shim box.

20 shims in total. From K&L.

BMW / KAWASAKI / YAMAHA

Ships same business day
$219.95
KLR650 '87 - '18

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.

Ships same business day
$9.95
KLR650 '87 - '18

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.

Ships same business day
$29.95

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!

Select Year and Color
Ships same business day
$139.95
KLR650 '87 - '18

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.

Ships same business day
$129.95

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.

Select Year
Ships same business day
$209.95

Complete Doohickey Replacement Kit now includes the outside cover gasket. Complete kit includes:

  • Doohickey from Eagle Manufacturing (No longer includes extension springs. The torsion spring is far superior)
  • Torsion spring with drill bit
  • Wrench to hold the rotor
  • Puller to remove the rotor
  • Replacement bolt for rotor
  • Generator cover gasket
  • Left side outer cover gasket
Please contact us for availability information
$154.95
KLR650 '87 - '18

The genuine Eagle Manufacturing balancer lever kit. All top quality components.

  • KLR650s have been known to have problems with the stock idle lever (doohickey) needed to keep tension on the balancer chain - failure of this part can destroy the engine
  • The Eagle Manufacturing idle-shaft lever and spring replaces the "weak" stock unit
  • One-piece design lever is Machined from 17-4PH hardened, stainless steel to be incredibly strong
  • Includes stainless doohickey, and the torsion spring with drill bit. (No longer includes extension springs. The torsion spring is far superior.)
Ships same business day
$59.95
KLR650 '87 - '18

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.

Please contact us for availability information
$13.95
KLR650 '87 - '18

Special tool to remove the flywheel/rotor from the end of the crankshaft. You have to remove the flywheel/rotor to upgrade the doohickey.

Ships in 3-5 business days
$14.95
KLR650 '87 - '18

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.

Please contact us for availability information
$50.95
KLR650 '87 - '95

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.

Select Year
Ships in 3-5 business days
$108.95

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.

Ships same business day
$848.95

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.

Choose Year
Ships in 1-2 weeks
$32.95
KLR650 '87 - '18

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.

Ships same business day
$22.95
KLR650 '87 - '18

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.

Ships same business day
$10.95

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.

Ships same business day
$39.95

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 $3.59 per filter with our value 5-pack!

Ships same business day
$17.95
KLR650 '84 - '18

Extra protection for your motor! Strong magnet at the end of the plug picks up metallic flakes in your oil, protecting your engine!

Ships same business day
$16.95

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.

Ships same business day
$10.95
KLR650 '08 - '18
  • Bolts are CNC-machined from high-quality aluminum
  • Embedded magnet helps keep bolt in place
  • Pre-drilled holes make for easy installation of safety wires
Please contact us for availability information
$25.95
KLR650 '87 - '18

A 10-pack of drain plug sealing crush washers. Replace your sealing washer at every oil change to prevent a leak.

Ships same business day
$6.95
Universal fit. May require additional adjustment or modification.

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, 14mm, 16mm, 18mm, 21mm.

Choose Size
Ships same business day
$14.95
KLR650 '87 - '18

E3 Resistor Spark Plugs

  • Unique electrode shape maximizes the power created by the spark plug – Diamond Fire technology
  • Electrode is a combination of performance and technology that results in an improved flame kernel shape
  • This flame front ignites the bulk air/fuel mixture faster, moves heat into the combustion chamber faster and creates a more localized pressure front for faster pressure rise during the cylinder power stroke
  • The result is more complete combustion and an improvement in engine performance
  • A truly premium performance plug
  • Sold individually, unless otherwise stated.
Add Anti-Seize
Ships same business day
$9.95
KLR650 '87 - '18

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.

  • High-quality materials and superior construction for serious power and reliability
    • Pure alumina silicate ceramic insulator provides high strength and better heat transfer
    • Deep-seated copper core for a wider heat range
    • Nickel alloy tip for longer life
    • Trivalent metal plating provides superior anti-corrosion and anti-seizing properties
  • Choosing the right high-quality plugs prevents fouling from running too cool and preignition from running too hot
  • NGK plugs available for almost every application and riding style
Add Anti-Seize
Ships same business day
$3.95
KLR650 '87 - '18

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.

  • The ultimate in the evolution of spark plug technology and performance from an industry leader
  • The iridium electrode is 25% smaller than a platinum electrode, and it's just 1/4 the size of a conventional nickel electrode
  • Ultra-small diameter center electrode reduces voltage requirement and extends ignition system life
  • Metal shell plating has enhanced anti corrosion qualities

Sold individually, unless otherwise stated.

Add Anti-Seize
Ships same business day
$11.95

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.

Select Year
Ships same business day
$49.95
Universal fit. May require additional adjustment or modification.
  • Contains degree wheel, standard unit indicator, adjustable magnetic stand, and three positive stops (10 mm, 12 mm and 14 mm threads)
  • Can be used to install and adjust timing of any cam
  • Wooden carrying case
Ships in 3-5 business days
$315.95
Universal fit. May require additional adjustment or modification.

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.

Ships same business day
$32.95
Universal fit. May require additional adjustment or modification.

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.

Ships in 3-5 business days
$112.95
Universal fit. May require additional adjustment or modification.

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.

Ships same business day
$13.95
Universal fit. May require additional adjustment or modification.

A 3-pack of easy to apply strips measure the temperature of engine, suspension, and radiator components. Temperature range 149° to 248°

Ships same business day
$14.95
Universal fit. May require additional adjustment or modification.

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.

Ships same business day
$5.95
Universal fit. May require additional adjustment or modification.
  • 26 straight blades
  • SAE and metric markings
  • Check for clearance on valves, ignition points etc.
  • Includes 26 blades varying in thickness from .0015"/.038 mm to .025"/.635 mm
Ships same business day
$12.95