A couple weeks ago, I finished the pictorial install for the 685cc piston kit from
www.schnitzracing.com.
I did the install on my '09 to hopefully stop the oil burning. I think the '07 and earlier models are similar enough that between these documents and the Clymer manual, you can use it for these as well.
Here's Schnitz's page on the 685cc kit. The links are about 1/4 of the way down the page.
Here are the pictorial install documents. (big PDFs)
Part 1 - DisassemblyPart 2 - ReassemblyI went riding with a fellow KLR owner Sunday. He had an older KLR, and said that mine was noticably more powerful and smoother.
Enjoy!
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