02/06/2026
Kawasaki klr650 2005 update. After some overtime hours in the garage at home the budget build klr650 is ready for a blue slip inspection and then registration.
Recap. Purchased for a case of beer off a customer after it sat since 2017 in his garage and needed a heap of work to get back on the road.
Work done over a 4 week period:
Initial thorough degrease, dismantle bike down to just engine in frame. Clean swingarm and subframe. Grease all bearings and pivot points, fork oil changed and fork dust boots refurbished, steering head bearings greased, airbox cleaned and a new air filter installed, wiring harness cleaned, various brackets sandblasted and painted, rims cleaned and new pirelli mt60 tyres installed, fuel tank cleaned, new fuel tap, carburettor rebuilt, new black handle bars and risers, new battery, engine serviced, new grips, fmf muffler repacked to quieten it down a little, exhaust pipe wire wheeled to clean it and heat shield painted black. New chain and sprockets, new rear brake master cylinder, new lower chain guard, seat given a good scrub, plastics which I was going to paint but decided I wouldn't incase the paint started peeling were cleaned, rubbed back with some 1200 wet/dry sand paper and soaked multiple times in Inox penetrant to give them some shine.
The above brings me to the test ride and shake down (on a closed private road of course 😁) and the klr650 proved why people love these older tractors.
It went ok for 45hp, brakes got better the more they bedded in although they're 21 yr old average at best for the time brakes.
Now the total spend for the budget build was only $1497 and 38 hrs of time spent over the 4 weeks since I collected it.
I'd say the klr650 budget build was a success and definitely an enjoyable exercise.
