I just bought this '02 KLR 650, 2285 miles, Progressive fork springs, Cycle Brake kit (larger rotor, EBC pads, caliper adapter, SS front line), bash plate, anti vibe mirror mounts and that's about it.

Here are some pics. Click to enlarge.

I'll be getting it shipped sometime this month or early next.

I got it and don't like it.

It's got 2,370 miles.

$3,500

Here are some pics as of as of 5/14/05

Well, that was my first one and I guess it was just too nice so I bought this '00.

I added the tank and just threw the saddle bags on it to get them out of my way while cleaning the garage.

More to come.

OK, I finally got time to work on KLR 2.

I decided to take a look at the original motor while it's still mounted.

I decided to pull the left side of the motor to see what I had.

The bike was purchased (not running) by a friend.

The original "Doo" was broken and the spring missing.

The new "Doo" was installed (not by me, but by my friend) and after some carb issues the bike fired up but made horrible knocking/banging noises.

I finally got a 10 second sound clip of the noise.

Click Here (Be ready, it's not pretty.)

This is where I grabbed the bike from him.

I pulled the left side of the motor apart to see if I could find the spring, and maybe any parts of the "Doo" that might still be inside the motor.

I found the spring.

While in there it looked like the counterbalance system was out of time.

I did not pull the valve cover, cams, cam chain, or anything else in the top end.

I didn't touch the right side of the motor either.

I lined up all the marks on the 3 different shafts and sprockets, put it all back together and it made the same horrible knocking/banging noises that it did before.

That made me think that it mattered which way the 2 punch marks on the crank were orientated.

They were lined up but I thought they might be 180˚out.

I took out the sprocket behind the "Doo", pulled the chain off the crank sprocket, spun the crank 180˚ (now the Woodruff key slot is at about 11 o'clock, lined up with the cylinder), and put it all back together.

Now it is still timed as per the manual and the Clymer book but the 2 punch marks on the crank sprocket are inverted.

Sill the same horrible knocking/banging noises.

If anybody would like to hear just what this motor sounds like I can call them any time after 6 pm EST.

Just drop me a number to CatfishRacing "@" CatfishRacing "dot" com.

I'm trying to get a sound byte for this page to make it a little easier.

Any ideas?

I have another motor of unknown history that I guess I'll throw in so I can really dig into this one but if I'm missing something stupid I'd rather fix the motor that's in it first.

If ya look close you can see that it's out of time.

Looks like it might have jumped 2 teeth.

I got all happy figuring that must be why it makes a racket and vibes really hard and really loud.

While I was at it I got this out of the lower end with a magnet.

Thanks.

Well, I swapped an older motor in the '00 and it has been running well ever since.

I loaned it to my buddy Jason and he proceeded to BLOW IT UP!!!

He said it made a bad noise so I figured it was just the Doohickey so I grabbed one out of stock and ran over to his house to toss it in quick and hope that there was nothing else torn up while we were in there.

I knew it was gonna be bad when we pulled the left side covers and the "Doo" was still good!

It didn't take us long to figure out that some other stuff in there wasn't right.

Here are some of the pics.

If you look close you'll see two of the "ears" missing off the counter balance weight.

Here they are along with some bits of a spring (not the "Doo" spring as that was fine) and 3 pieces of roller bearing. I don't know what roller bearing yet but I'll start looking tonight.

When the circlip holding the counter balance weight on the shaft failed the weight started to move left to right and MASHED the back side of the large sprocket on the crank shaft.

Anybody got one for sale?

CatfishRacing "@" CatfishRacing "dot" com

OK, it was more cost effective to purchase another motor and just do a swap.

Motor's in, bike is running, and most of the goodies have been swapped out to KLR 3!

Yup, that's right! I bought a sweet red '05 a few weeks ago.

KLR's should have only come in OD Green!!!

This page was last updated on:

01/24/2008