KAWASAKI KLR 650 A (Big Tank) 1993        

Rider Weight in Kilograms:

Ideal Fork Rate: kg/mm

Ideal Shock Rate: kg/mm

Stock Fork Spring Rate: 0.387 kg/mm

Stock Shock Spring Rate: 5.10 kg/mm


Ideal Rider Weight 59 kg

4 Stroke Engine 650 cc

Teflon Shaft Bushing - 14id x 16 x 15

Teflon Shaft Bushing - 14id x 16 x 15



Shock Seal Head Assembly 40 x 14 x 21.5

Shock Seal Head Assembly 40 x 14 x 21.5



Shock Preload Collar Spanner

Shock Preload Collar Spanner



Shock Oil Seal 14 x 30 x 5

Shock Oil Seal 14 x 30 x 5



Outer Guide Bush 38 x 12 x 2.0

Outer Guide Bush 38 x 12 x 2.0



KYB Tall Piston Band 40 x 10 x 1.2

KYB Tall Piston Band 40 x 10 x 1.2



KYB 12mm Rebound Check Valve

KYB 12mm Rebound Check Valve



Inner Slide Bush 38 x 20 x 1.0

Inner Slide Bush 38 x 20 x 1.0



Bump Stop Rubber 14 x 42 x 55

Bump Stop Rubber 14 x 42 x 55



20-038 Motorcycle Shock Spring
RRP $218.90
19-075 Motorcycle Fork Springs
RRP $218.90

The Kawasaki KLR650 has a proven track history, having only a few changes since 1986. We're not sure why they aren't more popular really, they are quite cost effective and comfy. While a Suzuki DR650 can be bought cheaper, most people then have to go get a bunch of aftermarket bits to make it more useful, but not so with the KLR. The headlight is properly bright (no DR candlelight). There's a windscreen already there, and being factory, it actually works! Quietly too, no squeaks or wind-noise, without buffeting a peaked helmet. Nice big fuel tank. Good handguards too. Blinkers that drivers can see. It's all very well thought out and works harmoniously, not just thrown together.
So if you want a budget adventure bike that you don't have to cobble together like a meccano set, we are offering special prices for the following package only:

KLR650 Upgrade. New Fork Springs, V4s Valves in Forks, Damper Rod Modifications. Revalved Stock KYB Shock, New Shock Spring.

Suspension Only $850
Ride In & Ride Out $950

Up to 2007, the forks were a very small 38mm diameter, and 2008 onwards saw an increase to 41mm. Both were Damper Rod Forks, which don't give any speed-sensitive damping, unlike more modern cartridge fork designs. One of the simplest solutions, without resorting to the huge cost and difficulty of grafting in cartridge forks, is to install what Kawasaki themselves used to call "Travel Control Valves" (they have also been called Gold Valves, PD Valves, Emulator Valves and a bunch of other stuff). We call them V4S Valves, and they help give damper rod forks some much needed speed sensitive damping.
  • Fork Revalve & Service with V4S Valves. Its not just any old service; the welding, the machining and the Teknik designed travel control valve system give huge benefits over the stock parts. It means that the front end feels less busy, and rather than dancing all over the place, feels stable and planted. After a long day in the saddle, your arms won't feel like jelly. Depending on your weight, and how much gear you carry, you may well need to change your fork springs to suit too. You can find the fork spring rate you need HERE.
From the factory, the 40mm KYB Shock is lightly damped and under-sprung, making for some trouble if you are heavy or intend to carry any gear.
  • Stock Shock Service & Revalve. While it doesn't sound as amazing as an adjustable replacement coilover shock, once we have gone through your old KYB shock with new parts and custom set the valving to suit you and your riding, the end result is a spectacular improvement for a much cheaper price. You will want a stiffer rear spring too; find the perfect shock spring rate HERE.
Extra Options
  • Accessories. Racks and other accessories can be found at Adventure Moto in Sydney NSW.
  • Large Fuel Tanks. While quite a popular mod, we don't actually recommend them. One, the stock tank is already quite large, about 300kms large. Two, it's just more weight over the front and over those poor old damper rod forks. It reduces the handling further, increasing understeer. Three, do you really want to adventure in so many places where there isn't a petrol station for more than 300kms? For most people it's overkill and your money is better spent elsewhere, in our humble opinion.
  • Tyre Selection. We like the Dunlop 952F front as the 650 does not give a lot of feel from the front, regardless of the fork setting. Dunlop D606 is the best all round rear. The Michelin HP4 is also a great front but not road legal, the T63 is a great rear choice too.

38mm OD

Kayaba (KYB) Conventional 38mm OD


Top Out Type External

212 mm

Fork Travel 212 mm

31.8 mm

Fork Tube Inner Diameter 31.8 mm


Emulator Preload Turns 4.0

64 N

Emulator Spring 64 N

38mm id x 20mm height x 1.0mm thick

Inner Bush Dimensions 38mm id x 20mm height x 1.0mm thick

38mm od x 12mm height x 2.0mm thick

Outer Bush Dimensions 38mm od x 12mm height x 2.0mm thick

12 x 18

Fork Damping Rod Base Copper Washer 12 x 18

30.8 mm

Fork Spring Large Outer Diameter 30.8 mm

30.8 mm

Fork Spring Small Outer Diameter 30.8 mm


Number of Coils 50.0

494 mm

Spring Free Length 494 mm

0.387 kg/mm

Spring Rate - Measured 0.387 kg/mm

142 mm

Spring Spacer Length 142 mm

4.26 mm

Spring Wire Diameter 4.26 mm

612 mm

Set Length 612 mm

15 mm

Standard Preload 15 mm


Fork Oil Weight 7.5

150 mm

Fork Oil Level 150 mm

2 Litres

Oil Quantity 2 Litres

40mm ID

Kayaba (KYB) 40mm ID


Shock Linkage Yes


Rebound Adjuster #2

142 psi

Nitrogen Pressure 142 psi

89 mm

Shock Travel 89 mm

14 mm

Shock Shaft Outer Diameter 14 mm

12 mm

Shock Shaft Outer Diameter at Valve 12 mm

M12 x 1.5

Shock Shaft Nut Thread M12 x 1.5

#55 (1.3mm)

Shock Piston Rebound Bleed #55 (1.3mm)

26 mm

Standard Preload 26 mm

85 mm

Standard Sag 85 mm

25 ft lbs (34 NM)

Shaft Nut Torque 25 ft lbs (34 NM)


OEM Spring Colour Black

250 mm

Spring Free Length 250 mm

56.3 mm

Shock Spring Large Inner Diameter 56.3 mm

56.3 mm

Shock Spring Small Inner Diameter 56.3 mm

55.3 mm

Shock Collar Large Outer Diameter 55.3 mm

55.4 mm

Shock Collar Small Outer Diameter 55.4 mm

221 mm

Spring Maximum Set Length 221 mm

211 mm

Spring Minimum Set Length 211 mm

5.10 kg/mm

Spring Rate - Measured 5.10 kg/mm