I've always said the KLR650 is a great motorcycle because it provides a low cost platform for almost any type of riding, even with claims about Must-Do engine mods. I never really bought into the "doohickey" and "thermobob" repairs you read about on forums, or hear about in YouTube videos. At least I don't think these claims are a common concern for 2nd and 3rd generation KLR's, which is why I never did these mods on my KLR, and it's never been a problem in 45k miles. In fact, I haven't done any engine mods. However, there appears to still be a problem with the KLR650 lurking in the darkness, and whether you find this hellish Easter egg seems to depend on how you ride your KLR.
I remember hearing about some early 2nd generation KLR 650's having an oil consumption problem, which was much worse at higher RPM's. I thought Kawasaki fixed it, but a recent review video of a 3rd generation KLR650 shows that this problem might still be there. I say "might" because your forced to take this person at his word, and you really don't know all the details. Here is what he said, and I'm going to refer to him as Bob.
Bob says he bought a 3rd generation KLR 650 strictly for traveling, and has traveled 68k miles. Bob usually travels around 75mph, but it's not uncommon for him to travel faster for long stretches of freeway. He did this for 20k to 30k miles, I can't remember which, then a problem with oil consumption appeared, and it got so bad he was using a quart of oil between gas fill ups. Eventually, he tore the top end apart and replaced the piston rings, and that fixed the problem. Bob also said he had bolts loosen up and fall out due to vibration at higher speeds, and his passenger foot peg wore out just from the vibration. Also worth noting, Bob never did the Doohickey and Thermobob repair.
I have experienced some motor oil consumption with my KLR, but it was never bad. I have a 2nd generation, 2009 KLR650 with close to 45k miles. Occasionally, I've added a few ounces of motor oil between oil changes, but it was never an amount that made me think the engine needed attention. The fastest speed I travel on the freeway is 65mph, but it's usually no more 60mph, and traveling on the freeway is rare for me except for a 1 mile stretch to get to town.
I don't know what Kawasaki was thinking advertising the KLR650 as an adventure motorcycle, and building an engine that develops an oil consumption problem if you travel fast on the freeway. The truth is, the KLR 650 is a dual sport motorcycle and is not designed for fast touring. Bob's passenger foot peg wearing out from vibration is proof of that. Whether they market the bike as a dual sport or adventure model, Kawasaki should fix these problems if they intend to keep the KLR 650 in their lineup. It's just the right thing to do.
