Kawasaki KLR-650 465 Series Single Shock Supplement

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Filed Under (Kawasaki) by admin on 13-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the opening between the main-frame and sub-frame on the left side of the bike. n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is facing the right side of the motorcycle and the pressure valve is facing forward. n On 1987-2007 models ONLY , install the supplied 3.5mm thick spacers – one on each side of the shock clevis ( see figure 3 ). Do not install these spacers on 2008-2010 models. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6- 1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m). Then mount the bracket to the bike using the two rear footrest mounting bolts – sandwiching the mounting bracket between the rear footrest mount and the frame tabs (as shown in figure 4) . Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. n To adjust the ride height, simply turn the adjuster knob clockwise (looking at it from the back of the bike) to increase the height and counterclockwise to reduce it. See main instructions for procedure of achieving optimum ride heigh

2008 KAWASAKI KLR 650 REAR LINE INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 13-01-2011

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The OEM brake line for your bike was routed behind / under the caliper. This caused the line to loop around the caliper. Your Galfer brake line is cut shorter so it can be routed down the swing arm and into the “C” clip pictured. This eliminates the extra hose that could get caught on a bush, tree, rock, etc. New Galfer “C” clip must be installed with the new hose using the existing stock bolt.

Kawasaki KLR 650 Hydraulic Clutch Installation Manual

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Filed Under (Yamaha) by admin on 08-11-2010

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Now, the clutch safety interlock switch. The picture above shows the safety switch contacts. Once you removed the 2 screws holding it to the stock lever, you will need to cut the copper plate on the switch. There are 3 wires: Green, Black with yellow and Blue. You do not use the green wire. You will need to attach the supplied terminals to the remaining wires and slip the supplied rubber boot over them as you attach them to the hydraulic clutch lever. In the photos, the boot is installed and also removed, and with my finger, I am pointing to its location. I did not bother to install the clutch interlock switch and removed the wiring harness completely, but unplugging it from the connector behind the instrument panel. Next, you must remove the clutch cable from the lever in order to pass the cable under the steering head he picture above shows the attachment at the clutch actuator Once the clutch cable is removed from the lever, remove the bolt holding it at on the engine case and disconnect the clutch cable from the pivot. The easiest way to do this is to pull out the clutch pivot assembly and the long “spike” out of the clutch plate hole. (It only goes back in one way, so you can’t mess it up.) he picture above shows that the routing is the same as the original clutch cable. With the hydraulic clutch assembly, pass the stainless steel braided line to the clutch “pivot” point at the engine casing. Attach the clutch cable to the “pivot” while it is removed from the engine, then insert the “spike” into the clutch plates hole (it can only go in one way).

Kawasaki KLR 650 Fork Brace Installation Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Place your motorcycle on its center stand or appropriate support stand. Slide up fork boot (if applicable) from fork leg. 2. Remove the two outer caps (6mm x 16mm bolts), and slightly loosen the inner bridge mounting bolts (6mm x 50mm bolts). 3. Position the Fork Brace assembly, so it is level side to side. Then fasten the outer caps on each side making sure it is resting all the way down on the fork tubes. The spacers provide MUST be used for adequate tire clearance. 4. Now check the bridge if it is free of tension. Move your front forks through the suspension travel. 5. Tighten the inner bridge bolts securely, and then collapse the forks completely to check for interference with any accessories or fender. Make sure you have nothing causing your suspension to bind. Slip your fork boots over the Fork Brace. Installation is now complete. Double check all nuts and bolts for tightness. Recheck all nuts and bolts after a short test ride. Periodically check bolts as part of your pre-ride inspection. * WARNING: Ride stability and handling will be greatly improved with Fork Brace, provided your motorcycle complies with the manufactures specifications. BE SURE that the front tire is properly inflated and balanced, and not out-of-round. Check to see that front and rear suspension air pressure and oil levels are correct. Failure to comply with any or all set standards may adversely affect the handling of your motorcycle

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KAWASAKI KLR 650 SADDLEBAG INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 24-10-2010

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INSTALLATION INSTRUCTIONS Place the saddlebags on the rear of the seat. Adjust the velcro connections over the seat as necessary. Thread the rear strap as seen in photo 1. and connect the buckles. Cinch and tuck the excess webbing as necessary. Thread the front strap down and through the foot guard as seen in photo 2. ® 5-7-07 WARRANTY INFORMATION Your new Kawasaki accessory is guaranteed to be free from defects in material and workmanship for 90 days from date of purchase. CARE & CLEANING Do not carry sharp or pointed objects. Maximum Weight-5 lbs. (2.2 kg.) Each bag Be sure the saddlebags do not interfere with any operarating or wiring components. Photo 1. Photo 2. ISK57003100/R1