SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Left Side Engine Component Removal
Flywheel and Starter Clutch
Remove the magneto cover bolts using an 8 mm wrench.
The flywheel magnet is very strong and may make it difficult to remove the cover. If necessary, use a rubber mallet to break the cover free. Be careful not to damage the cover.
On electric start models, remove the inner magneto cover using an 8 mm wrench.
Remove the flywheel bolt using a 19 mm socket. A pneumatic impact driver will do the job nicely.
Use a commercially available flywheel puller to remove the flywheel. Grease the flywheel puller threads and thread the puller completely into the flywheel. Using the flats on the flywheel center to hold the flywheel from turning with a wrench, tighten the puller until the flywheel breaks free. A sharp tap with a steel hammer on the end of the flywheel puller bolt will help dislodge the flywheel. This particular flywheel puller fits several motorcycles in addition to the Kawasaki KLR650.
Note: Do not strike the flywheel itself or the magnets could be damaged.
Remove the flywheel and inspect the starter clutch gear and bushing for wear or damage. Replace parts as needed.
Inspect the woodruff key and crankshaft woodruff key slot for damage. Remove the washer from the end of the crankshaft.
Starter Motor Reduction Gears
Remove the lower reduction gear thrust washer.
Remove the reduction gear.
Remove the lower reduction gear shaft and bearings.
Remove the upper reduction gear thrust washer.
Remove the reduction gear and inner thrust washer.
Left Side Balancer Components
The Kawasaki KLR650 engine has two chain driven balancers. The idler gear and chain tensioner are pictured at the bottom of the photo.
Pull the cam chain off of the crankshaft sprocket and remove the cam chain.
Remove the balancer chain tensioner adjuster using a 10 mm wrench.
Remove the balancer chain tensioner spring by pulling it out with a pair of pliers.
Remove the idler sprocket shaft by pulling it out with a pair of pliers. Remove the washer.
Inspect the idler sprocket shaft, washer and bearing for wear or damage. Replace as needed.
Remove the idler gear.
Remove the front balancer weight snap ring using a pair of external snap ring pliers.
Remove the front balancer weight and sprocket assembly.
Remove the rear balancer sprocket snap ring using a pair of external snap ring pliers.
Remove the thrust washer.
Remove the rear balancer sprocket.
Remove the thrust washer.
Left Side Engine Component Installation
Position the crankshaft so that the punch mark lines up with the TDC index line on the crankcase. The crank must stay in this position to achieve correct balancer timing.
The balancer chain has a built in guide to assist in setting the timing correctly. There are five polished links on the balancer chain. There are two sets of two polished links, and then a single polished link on its own. The single polished link should be positioned on the crankshaft balancer timing sprocket directly across from the timing punch mark. The sets of two polished links should sit to each side of the punch marks on the upper and lower balancer sprockets.
Install the thrust washer on the rear balancer shaft.
Loop the balancer chain around the rear balancer sprocket and slide the sprocket onto the shaft.
Line up the punch marks on the sprocket and upper balancer shaft as shown. There should be a polished chain link on each side of the punch mark.
Place the outer thrust washer into position.
Install the snap ring using a pair of external snap ring pliers. Make sure the snap ring is fully seated in its groove.
Line up the punch marks on the left balancer weight and the lower balancer shaft. Loop the balancer chain around the front balancer sprocket, slide the weight and sprocket assembly onto the balancer shaft. There should be a polished chain link on each side of the mark.
Install the snap ring, making sure it is fully seated in its groove.
Note: Failure to align the timing marks will cause the engine to vibrate excessively.
Place the idler sprocket in position. Place the idler sprocket bearing into the sprocket.
Install the thrust washer and sprocket shaft.
Install the balancer chain tensioner spring.
Install the balancer chain tensioner adjuster. The tensioner spring should automatically tension the balancer chain. Tighten the tensioner adjuster securely.
Loop the cam chain around the sprocket on the crankshaft.
Place the woodruff key in the crankshaft woodruff keyway.
Slide the flywheel/starter clutch assembly onto the crankshaft, making sure to align the slot in the flywheel with the woodruff key.
Install the flywheel bolt, hold the flywheel in place using a wrench on the flats of the flywheel center and torque the flywheel bolt to specification with a 19 mm socket.
Flywheel bolt torque: 175 N-m or 130 ft-lb
Install the reduction gear and inner thrust washer.
Install the upper reduction gear thrust washer.
Install the lower reduction gear shaft and bearings.
Slide the lower reduction gear in place and install the thrust washer. The lower reduction gear has only one thrust washer.
Install a new magneto cover gasket and place the magneto cover in position.
The flywheel magnet will try to pull the cover in, make sure the gasket is still in place when the cover is in position.
Install the bolts and torque them to specification.
Left engine cover bolt torque: 9.8 N-m or 87 in-lb