KLR 650 Fairing Removal and Disassembly | Field Stripping the KLR 650 | Maintenance | Island ADV

KLR 650 Fairing Removal and Disassembly | Field Stripping the KLR 650 | Maintenance | Island ADV
The first step to tweaking and modding a Kawasaki KLR 650 is getting through all the plastic fairings. Here’s how I tear down and field strip the bike for mods and installs.
NOTE: While I am not a mechanic, I love to work on my bike and I encourage you to learn more about yours as well. However, if you ever get in too deep and feel like you messed something up, ALWAYS seek out a trained mechanic to work on your machine. Be safe, use PPE, have fun.
Chapters:
00:00 Intro
01:09 Rear Side Fairings
02:19 Seat Removal
02:56 Front Side Fairings
05:04 Need Well Nuts?
07:27 Cowl Removal
12:01 Fuel Tank Removal
15:25 Things to Consider
NEED WELL NUTS??
Get 'em here:
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[@evenstevenmotodrone735]

Thanks Eric, very well explained... I may DIY paint mine.... This video may help

[@IslandADV]

Thanks man. I love your Tengai style paint scheme. It's so cool.

[@BabineauMoto]

Great instructional video. This will be very helpful for all KRL650 owners.

[@IslandADV]

I hope so man. I remember I had to watch like four different videos years ago to figure this all out. Here's hoping this shortens the way for others someday.

[@Laurie-cy4hb]

One of the easiest and straight to the point UTube clips I have seen.

[@IslandADV]

Thanks so much! I really hope it helped out a bit.

[@black_widow_overland]

Very good tear down video. 🤘🏼

[@IslandADV]

Thanks brother. I hope it helps someone out.

[@stevenn1337]

Great video! I never have a problem tearing mine apart, its the putting back together I struggle with 😆

[@IslandADV]

It always seems to be the way right? My trickiest part is that one front fairing bolt that goes through the radiator and guard. The way it's right behind the crash bar on my bike is foolish, lol.

[@kentuckyadv]

Thanks for sharing this! Very informative. I love how you explain the process.

[@IslandADV]

I'm glad you enjoyed it. Hopefully it proves useful to someone down the road. Cheers brother.

[@garygibson8427]

Great video a lot of good info.

[@IslandADV]

Thanks brother. I was taking the bike apart the other day and figured I'd set the cameras up and record. I know a similar video helped me in the past, so I added some of my tips to this one.

[@advphilnb]

Yessir! Great tear down video. That would have been helpful the first few times worked on my KLR... lessons learned I guess, lol. Thanks for sharing, and keep well!

[@IslandADV]

Thanks. I'm hoping it'll be a good video to reference in the future when I start out with the bike all torn down already. Cheers brother. Hope your winter's going well.

[@frank_jk]

I’m tearing into my KLR for the first time today and your video has been so helpful. Thank you! I’ve learned so much. Also, I like your little parts box for the hardware.

[@IslandADV]

Oh nice. I'm glad this helped out a bit. And yeah, the little fastener box is key for me. My huge freak hands drop stuff all the time, lol.

[@Call_Me_Dragon]

Thanks

[@IslandADV]

You're very welcome.

[@rustedjunkgarage3316]

Great video, 💯🆒

[@IslandADV]

Thanks so much!

[@Thejohnmullen]

I’m actually in the process of trying to get a stuck wellnut out so I can install my klr dash…

[@IslandADV]

Oh those are such a pain in the butt. I have a little drawer in my hardware bins that are full of well nuts. I've had a few get stuck in the past too.

[@AdventureTomek]

Sure just a reverse process 😂 maybe its just me, but I seem to never have an easy time putting mine back together. Nice job!

[@IslandADV]

Lol, I think I have mine broken in now. There's only a few trouble spots when I reassemble it these days.

[@AdventureTomek]

@@IslandADV I found the hardest thing for me was putting the front rim and tire on and trying to get that damn speedometer hub aligned, as well as the hub itself on the fork notch 😖

[@MCCJustMotos]

Great reference video! Do you store your bolts all together, plastic bag & marker them? Screw them back in?

[@IslandADV]

Thanks. I use almost like a fishing tackle box to keep them all together. Each segmented storage spot is labeled with what they are for. It helps for keeping them all together when the bike is left torn down like this for an extended period of time.

[@MCCJustMotos]

@@IslandADV that’s a good system. I’m usually a plastic bag and marker on tape, but recently I do try and re-insert the bolts back into the piece when taken apart and left for a longer timeZ

[@Wilje]

Hey Eric, have you ever thought about drilling through the rear fairing so that you can remove the seat without removing the plastics? Also, have you done the PVC toolkit?

[@IslandADV]

That's cool idea. I never thought of creating an access point for those seat bolts. I'd really like to get a tool tube going as well. Mason (Mason's ADV) has a really good design for one using a tractor tool tube that goes under the rear fairing. There's some fairing cutting involved, but it's a great spot for tools or even a spare fuel cannister. I think both of these are on my list now, lol.

[@IslandADV]

In other news, I was doing a bit of pruning the other day when it was warmer and I was totally flashbacking to Freddy summers in the 99 with the crew. Miss those days.

[@dune_strider3055]

The well nuts on the cowl seem to be overnighted on my klr. How can I reseat them? This is a fantastic video, but I have no idea how to fix this issue. I don’t want to bug you, but I would like some help, and don’t know where else to ask, thank you.

[@IslandADV]

Oh like they popped out of the mount? If so you might be able to push them back in. It's tricky, but if you put some water on the rubber, it makes it easier to get them back in. You'll know it's in when you hear that little rib pop into place. If the well nut keeps turning and never tightens, see if you can reach your finger back behind the well nut to hold it in place while you screw the bolt in. This will allow it to compress and seat in, tightening everything up.

[@dune_strider3055]

@@IslandADV. They came out. Thank you!

[@IslandADV]

@@dune_strider3055 Sweet!!! Great job!

[@johnnyrebel1617]

I`m struggling to find the right well nut that goes inside the left fairing and the right well nut that goes on the bottom of the right fairing. Both of them were damaged by the ex owner since i got the bike.

[@IslandADV]

These should be 6mm rubber well nuts that you'll need. Check out this link for some M6 well nuts. These might do the trick. www.amazon.ca/gp/product/B07F71HTK4/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 Also check this site out. This is my goto for looking up tiny parts to get an idea on clues for searching for them around the internet. www.kawasakipartshouse.com/oemparts/l/kaw/5af06f9687a86610d0133b6b/2018-klr650-kl650ejs-parts Well nuts can be tricky to get in place too so good luck. You got this!

[@AndyADVenture]

Using loctite on the well nuts I've made that mistake not fun lol

[@IslandADV]

I was super bummed when I had my two at the cowl seize. Rode with zip ties before I could get some replacement well nuts. It was a pain indeed.