SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Remove the front wheel. See the Front Wheel Removal topic for more information.
Removal
To remove the front wheel bearings remove the outer dust seal using a seal puller or a large flat blade screwdriver. Always replace the dust seals if replacing the wheel bearings.
Remove the snap ring that secures the bearing in place on the left side of the hub using a pair of internal snap ring pliers.
Use a bearing removal tool to extract the front wheel bearings or drive them out using a punch and hammer. The wheel in the photo on the right is not from the Kawasaki KLR650, but the procedures are the same.
Installation
NOTE: Before installing the new wheel bearings, put them in a freezer for one hour, this will make installation easier.
Apply grease to the inner lip and back of each dust seal before installation.
Install the left side wheel bearing and then the distance collar followed by the right side bearing. Use either a bearing driver or a socket with the same outside diameter as the OD of the bearing. Using a seal driver install the dust seals. If a seal driver is not available, you can use a socket that fits the outer diameter of the dust seal. />