In this video I film myself getting down to the clutch of my KLR650. To do that you will need to drain the oil from the engine, and the water from the radiator. This is a project that might seem a bit overwhelming at first, but if you take it one step at a time you should be able to handle it. Take the skid plate off, drain the oil, drain the water, and start taking out all the bolts in your way. Once you have everything out you will probably need a rubber mallet or something to jar the side casing loose. Mine took a little pounding before it would come off. Make sure to clean out the little filter while you are in there. Clean the old gasket off everywhere it stuck to the metal. Be careful when you are cleaning it off not to damage the O-ring that is in the side case.
Don’t forget to buy new gaskets when you do this job. I didn’t realize I needed them, and had to wait a few weeks for them to arrive before I could put the bike back together. One of the joys of living in Panama… You will need the big gasket for the side case, and a small one for the water pump.
For detailed instructions including tools and parts needed for this procedure check out: http://www.ravenshadow.com/KLR650/techtips.html I looked at it a few times while doing this project and it helped, but since there isn’t a video, or even any pictures I decided to post this so people could see what they will be getting into.
