Removing engine restriction from AUSTRALIAN KLR?

[Copywrite]

Hi all.

I've reached the time in every 08 KLR's life when it must get it's 1000km (600mi) service. This first service i'm going to get done at the dealership, then i'll start doing them myself. On top of this the dealer has quoted me AU$175 to de-restrict the bike, he reckons it adds another 10-15hp. Is this true, or is he telling me porkies? I'd like to get this done, but i don't really want to pay what they're asking. Is this something that can be done at home? If there's an existing guide to it somewhere on the board that someone can direct me to i would be most appreciative. I've done a search but i may be using the wrong lingo.

Thanks in advance

[Nuclieye]

Your kidding right? A "restricted" KLR?????

A strong headwind does the same thing.

[Copywrite]

If i was kidding, i'd say " two engineers walked into a bar. You'd think one of them would have seen it". But thanks for the informative, intelligent and well thought out post. As a new KLR owner i can see your knowledge on the subject is truly awesome, and you've really gone a long way toward answering my questions

Anyone else actually got anything useful to share?

[jeffsaline]

I'd be asking the dealer what de-restrict the bike means. They should be able to tell you'll what they'll do in general terms if not specifics. I'd be asking for a before and after dyno run as I think they are yanking your chain. To the best of my knowledge there is not much you can do to a stock KLR to get 10-15 more hp.

Best,

Jeff

[fixer]

England has restricted bikes, not a huge surprise that the Aussies do too.

it's PROBABLY a restrictor plate in the intake. probably requires pulling the carb, pulling the intake and then putting it back together with the restrictor left out.

can you post a pic of the carb and intake? we should be able to see something there.

also, check under the air filter in the airbox... it might be there, and if so, then it's gonna be MUCH faster to remove it.

you might check the fiche for the AUS version and see if it shows the restrictor... post a link if you find that.

[cycle_cop]

wow, 10-15 HP for that price? So maybe he told you a little white lie

Save your money, you wont get 10-15 HP from the dealer like that. You can do most of the work your looking for at home.
1) Do a carb shimming, just do a search and it basically explains itself.
2) Do the "L Mod", again pretty simple
3) Pull your Snorkle
4) change your air filter to something less restrictive, you can also remove the metal screen behind the filter for better air flow ive heard.

Other than that, you can of course add aftermarket exhaust to help it breath a little better. Hope this helped.


Edited - Just saw that you were from Australia, took for granted you were in the U.S., so i guess being "restricted" could mean anything huh? I wiould ask the dealer exactly is done for your money, and then go from there!

[fixer]

no fiche listed here www.kawasaki.com.au

[Judjonzz]

The KLR650 Supplement (mine goes through '95, but applies to those through '07 in most respects) shows an Australian version rated at 44PS, while the standard version is rated at 48PS. There is a 27PS German version, FWIW.

The nature of any restrictions that would account for the difference in output is not readily apparent. I dunno if '96 and later Aussie bikes were restricted further than that, but you are well-advised to question what the dealer is telling you.

[AmazingJas]

The aussie version certainly is restricted, my dealer did it for me for free, but it is easy enough to do on your own. I'm sure I got a tutorial off the www somewhere for this, but not sure where it is now.

Quick summary:

1. Remove seat and petrol tank (make sure you turn the tap off, and disconnect both main and reserve fuel lines first). Not essential, but much easier this way.
2. Loosen rubber inlet/outlet clamps on the carbie.
3. Undo the throttle cable bracket, and disconnect the two cables from the carb.
3. Twist carbie to the side so you can unscrew the bolts on the top of it.
4. Take the top off it, and remove the carb slide.
5. You'll find two holes on the slide, drilled towards the top of it. Fill them up with "liquid metal', making sure the outer surface is still nice and flush, though the inner part of the slide can have a bit more 'bog' in it. Wait for it to set.
6. Put it all back together, though you might want to consider shimming and drilling the slide while you are there...there is a tutorial on this forum for that already.

You will notice a huge difference straight away.

[aussiedav]

Jas handy stuff thanks. btw has anyone told you how annoying that flashing thing is when you are trying to read a post

[KLR-dude]

Originally Posted by AmazingJas

The aussie version certainly is restricted, my dealer did it for me for free, but it is easy enough to do on your own. I'm sure I got a tutorial off the www somewhere for this, but not sure where it is now.

Quick summary:

1. Remove seat and petrol tank (make sure you turn the tap off, and disconnect both main and reserve fuel lines first). Not essential, but much easier this way.
2. Loosen rubber inlet/outlet clamps on the carbie.
3. Undo the throttle cable bracket, and disconnect the two cables from the carb.
3. Twist carbie to the side so you can unscrew the bolts on the top of it.
4. Take the top off it, and remove the carb slide.
5. You'll find two holes on the slide, drilled towards the top of it. Fill them up with "liquid metal', making sure the outer surface is still nice and flush, though the inner part of the slide can have a bit more 'bog' in it. Wait for it to set.
6. Put it all back together, though you might want to consider shimming and drilling the slide while you are there...there is a tutorial on this forum for that already.

You will notice a huge difference straight away.

this is very interesting.

now why in the world would they restrict a bike like that,...what is the reason

[Copywrite]

Excellent info guys, thanks heaps. I'm not sure if it's something i'm game to try right now, i was scared off working on carbies back in the vb commodore days. Certainly not paying the stealer $175 to do it though. Once again thanks for the info, see you on the road.

Cheers

[Ozrob]

Hi,
In item number 5...where are the holes exactly that need to be filled, on the top or the side of the card slide, as with my 08 KLR Oz spec I did not notice any holes apart from the one on the top of the slide...perhaps I am blind???
The .22cent mod and fitting a 150 main jet does wonders.
Cheers
Rob

Originally Posted by AmazingJas

The aussie version certainly is restricted, my dealer did it for me for free, but it is easy enough to do on your own. I'm sure I got a tutorial off the www somewhere for this, but not sure where it is now.

Quick summary:

1. Remove seat and petrol tank (make sure you turn the tap off, and disconnect both main and reserve fuel lines first). Not essential, but much easier this way.
2. Loosen rubber inlet/outlet clamps on the carbie.
3. Undo the throttle cable bracket, and disconnect the two cables from the carb.
3. Twist carbie to the side so you can unscrew the bolts on the top of it.
4. Take the top off it, and remove the carb slide.
5. You'll find two holes on the slide, drilled towards the top of it. Fill them up with "liquid metal', making sure the outer surface is still nice and flush, though the inner part of the slide can have a bit more 'bog' in it. Wait for it to set.
6. Put it all back together, though you might want to consider shimming and drilling the slide while you are there...there is a tutorial on this forum for that already.

You will notice a huge difference straight away.

[jasklr]

Does anyone know when they started restricting OZ KLR's? DAMN i might have to pull mine out and inspect it. mine is 87 but i have a newer carby.

[fixer]

Originally Posted by KLR-dude

now why in the world would they restrict a bike like that,...what is the reason

i think it's a licensing issue for n00b riders.

instead of limiting them to a small displacement bike, they "allow" them to get a larger displacement bike, but one that's restricted in power.

while here, we let any rookie rider who can afford it walk in and buy a 100+ HP sports bike.

while i'm not aa fan of state limitations o what i can buy... gotta say that Darwin and Murphy sure love the n00b/squid riders on the higher performance bikes!