I am thinking about buying a Kawasaki KLR 650. I will buy one used. What year should I look for?

Question

I know that they make slight changes on them from year to year, so what year should I look for? What else should I look for? I have only been riding about a year so I know that this is the one that I want. Any thoughts? Thanks for looking!

Answer 1

The KLR650 has been a solid bike since it's inception.
There haven't been many engine modifications along the way.
Mostly cosmetic.
Kawasaki got it right the first time.
Buy the one in the best condition and low mileage.

Answer 2

Mechanically they are all identical from 1987 onwards. They have had some changes to bodywork in that period but they came back to the original design about 2 years ago.
Looking secondhand, find one with servicing log books and some extra aftermarket things on it to suit what you are going to be using it for, eg. stainless steel muffler, carryrack, heated handgrips, hand guards, road tyres/knobbies,sheepskin seat cover, etc, so you dont have to spend extra money setting it up to suit you.

KLR650 ISSUES:

Rear Brake: The pins on the rear brake caliper mounts can wear causing the caliper to twist when applying the brake causing the pads to wear unevenly and have a short life span it also causes excessive wear of the disk so keep the pins lubricated with anti sieze to reduce wear.
CURE: A new caliper and mount is the only cure.

Balance Shaft Chain: The balance shaft chain adjuster must be adjusted correctly because too much slack in the chain will cause it to break and it is a big expensive job to replace it.
CURE:Get it checked at every service and use a mechanic that understands how it works. The adjuster is spring loaded so it is just a matter of loosening and tightening the adjuster bolt.

Coolant: If the engine coolant isn't kept fresh the cylinder head will corrode and leak meaning it must be replaced. Even using a second hand cylinder head it will still be an expensive job.
CURE: Use a quality coolant and replace it at every service.

Fork Seals: The fork seals can leak if they are old or have a hard life, causing suspension oil to leak down the forks onto the front brakes causing brake failure.
CURE: Replace the fork seals at the first sign of any leakage. It is a relatively simple quick cheap job.

Stearing Head Bearings: As with any motorcycle, if it has been used for too many wheelies the steering head bearings will become notchy and need replacement.
CURE: Dont do too many big wheelies and get the steering head bearings repacked with fresh grease at least every 2 years.

Rust In Petrol Tank: Small amounts of condensation can cause rust to form in the lower seams of the petrol tank causing fuel leaks, check the tank carefully for patches, repairs and leak proofing inside the tank before you buy a KLR650.
CURE:Replace the tank with a new one (expensive) or treat the tank with leak proofing like epirez or similar. A repaired or leak proofed tank is not a bad sign but it does mean the possibility of further leaks in that tank if the repair was not performed correctly.

Seat: The seat height is rather tall and the seat is wide as well making for a long reach to the ground especially if you stall the engine riding over an obstacle. Although the seat is nice and wide it can get a bit uncomfortable on longer trips.
CURE: Unless you are already over 7ft tall grow longer legs.LoL! Set the rear suspension on the softest settings to reduce the height of the rear of the bike and slide the forks up through the triple clamps.( get a mechanic to setup the forks so the wheel doesnt collide with the front mudguard at full compression.) For comfort invest in a sheepskin or gel seat cover.

Cables: The cables for the clutch and speedo will break if they are not kept well lubricated or are old.
CURE: Lubricate the cables often. You can get a small tool to attach to the end of the cables that will allow you to attach a pressure pack spray can to the cable and spray lube(WD40, INOX, ETC.) through the cable.

RECOMMENDATIONS:
Change the engine oil every 5000km (approx 3000miles) with a quality oil to keep the engine in good condition and the coolant every 10,000km (approx 6000miles) to prevent corrosion, your engine will repay you with reliable service for a long time.

Fit road tyres to it sometime and take it to the boy racers favorite scratching road in your area and watch them all cry when you whip them in the corners, just remember to brake early and get on the gas early and you can fly around corners on a KLR650 much faster than you thought was possible. I regularly beat 600 supersport bikes through the corners on my local racetrack at ride days.

Answer 3

I don't belive there have been any major changes to the KLR for a long time, mainly cosmetic stuff.

If going used make sure the "doohickey" has been replaced. More commonly known as the cam chain tensioner.

Answer 4

Generally speaking, manufacturers improve their products each year, so without knowing specifics, I'd say, go newer. But it depends on the condition of the individual machine -- an older, well-maintained machine is a LOT better than a newer one that's been beaten.