anxiety threshold for funny noise

[xs650@dejazzd.com]

I bought a laid down 93 over the winter and have been working on it for a while. It had more cosmetic damage than anything, and seemd to run pretty well. After a bit of sorting out, I decided to take care of the cosmetic issues, and now another green monster is on the prowl thanks to Dual Star and the take-off Y2K parts. The instrument cluster and controls were damaged, so a KLR600 instrument cluster replaces the 650 unit. This required fabricating a mounting bracket since the correct one didn't come with the bike. A bit of velcro and some vinyl fabric cover the mount and protect the wiring connectors from water. The fuse holders have been replaced with inline weatherproof mini fuse units that now reside behind the fairing. A manual fan over-ride(push/pull switch) is also wired in. A 40 ohm resistor inline with the temp sending unit makes the gauge a bit more accurate. A Supertrapp IDS2 with 9 disks replaces the stock muffler. A Twinair filter resides in the stock airbox. The pilot screw plug was drilled out, and the screw backed out an additional 1 or 1.5 turns...can't remember exactly, but I have no surging, and the plug looks good. I removed the extra plumbing and cannister for the Ca emission stuff prior, but would have had to for the new tank anyway. The replacement choke lever didn't clear the tank with the low aluminum bars that were on the bike, so I recycled the stock set from a 76 XS650 at least temporarily. They're higher and narrower than normal on a DS type bike, but quite comfortable. Progrip 737 gel grips worked well on my XT500, so I'm using them on the KLR as well. The petcock was leaking badly, so the diaphram was removed. The carb overflowed so resetting the float level cured that. I added an inline fuel filter. A Maier black ABS plastic fender is mounted low over the front wheel by way of clamps that also hold the new black fork boots. The stock shifter is a stamped out POS, and had been welded, so a Dual Star unit now resides in its place. I also added the DS radiatior guard. While I had the tank off, I decided to check the valve clearances. It was running smoothly and quietly, but I needed to know. Right sides were .006" and .008" while left was .007" and .012" for the intake and exhaust respectively, and with 15K miles on the engine I doubt that they'll be moving much soon. Unlike a lot of others, I haven't noticed vibration, engine noise, or front end oscillation. My front brake seems plenty powerful without upgrading to even a braided line, and while the forks dive a bit under heavy braking, I'm guessing there may be aftermarket springs inside. Mods that I'm considering are a real bashplate, and a firmer seat. Eric Stevens Mechanicsburg, Pa

[Ron Klimoff]

You gotta post some pictures of this thing... Ron NJ

--- In DSN_klr650@yahoogroups.com, wrote: > I bought a laid down 93 over the winter and have been working on it for a while. It had more cosmetic damage than anything, and seemd to run pretty well. After a bit of sorting out, I decided to take care of the cosmetic issues, and now another green monster is on the prowl thanks to Dual Star and the take-off Y2K parts. > > The instrument cluster and controls were damaged, so a KLR600 instrument cluster replaces the 650 unit. This required fabricating a mounting bracket since the correct one didn't come with the bike. A bit of velcro and some vinyl fabric cover the mount and protect the wiring connectors from water. The fuse holders have been replaced with inline weatherproof mini fuse units that now reside behind the fairing. A manual fan over-ride(push/pull switch) is also wired in. A 40 ohm resistor inline with the temp sending unit makes the gauge a bit more accurate. > > A Supertrapp IDS2 with 9 disks replaces the stock muffler. A Twinair filter resides in the stock airbox. The pilot screw plug was drilled out, and the screw backed out an additional 1 or 1.5 turns...can't remember exactly, but I have no surging, and the plug looks good. I removed the extra plumbing and cannister for the Ca emission stuff prior, but would have had to for the new tank anyway. > > The replacement choke lever didn't clear the tank with the low aluminum bars that were on the bike, so I recycled the stock set from a 76 XS650 at least temporarily. They're higher and narrower than normal on a DS type bike, but quite comfortable. Progrip 737 gel grips worked well on my XT500, so I'm using them on the KLR as well. > > The petcock was leaking badly, so the diaphram was removed. The carb overflowed so resetting the float level cured that. I added an inline fuel filter. > > A Maier black ABS plastic fender is mounted low over the front wheel by way of clamps that also hold the new black fork boots. > > The stock shifter is a stamped out POS, and had been welded, so a Dual Star unit now resides in its place. I also added the DS radiatior guard. > > While I had the tank off, I decided to check the valve clearances. It was running smoothly and quietly, but I needed to know. Right sides were .006" and .008" while left was .007" and .012" for the intake and exhaust respectively, and with 15K miles on the engine I doubt that they'll be moving much soon. > > Unlike a lot of others, I haven't noticed vibration, engine noise, or front end oscillation. My front brake seems plenty powerful without upgrading to even a braided line, and while the forks dive a bit under heavy braking, I'm guessing there may be aftermarket springs inside. > > Mods that I'm considering are a real bashplate, and a firmer seat. > > Eric Stevens > Mechanicsburg, Pa

[tehamaddmh]

I got a 2002 KLR 650 (9000 mi) about a week ago. I changed the oil & filter, went through dohickey tension adjusting procedure from manual (hadn't found Sage at that point), and checked chain tension, fluid levels, etc. I've ridden bike about 300 miles ( 1 150 mile trip through Lassen National Park the rest 20-30 mile rides. The engine runs strong & sounds great at highway speed. My anxiety is from an unexplained noise that occurs at about 20 mph mostly in 2d gear. The bike is basically at idle at that point the noise is sporadic / irregular @ sounds like hollow clunk or rumble. The only time I have heard this before was with a yamaha DT 360 enduro with bearing issues. The bike came with a 90 day "50/50" warranty from authorized kawasaki dealer. Any recommendations? thanks Richard