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Old 05-24-2011, 04:39 PM   #1
RevBill OP
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Joined: May 2008
Location: Mayodan, NC
Oddometer: 2,123
'06 KLR650 .. Toxic Green Adventure Bike ..

.. just to have some fun and ask some questions along the way .. since I hope a few of the avid (or rabid) KLR owners out there will follow along .. this is the bike I have wanted for a long long time .. and I finally found me one .. and '06 KLR650 from another inmate here on the ADV site ..

.. the day I picked her up .. about as "plain-Jane" an '06 as you can find .. and very clean .. (edit 07-11-2012) - I wish I had written it down, or maybe I have mentioned it somewhere else .. she had about 16,500 miles on her when I got her .. now she has just turned 24,000 in July 2012 and I am still in love with this bike .. though she has changed a little since I first got her ..


.. the proud new owner ..


.. had her for a few days and already out playing NC Tag-a-Rama ..


Just a tad over a year later and still playing tag games .. this was for the NCNCTAR game this past week .. a recreation of the first tag shot I played over a year earlier ..



Farkle List - As of 07/2012 - (Edited 02-13-2013)
01. BarkBusters - Twisted Throttle - Installed 05-05-11 and tested 05-07-11.
02. Rox Risers - 2" adjustable Rox Risers - Done - installed with new handlebars - 05/2012.
03. RAM Ball 10mm mount (originally on Choke Relocator, now installed on Rox Risers) - Twisted Throttle - Installed 05-13-11.
04. USMC Rear Shock - Done 6-24-2011.
05. RAM Ball Mount for Storm Case/GPS - Twisted Throttle - Installed 05-31-11.
06. Headlight Guard - TCI Products - Installed 05-11-11.
07. Crash Bars - SW Motech/Twisted Throttle - Installed 05-11-11.
08. Skid Plate - SW Motech/Twisted Throttle - Installed 05-28-11.
09. Center Stand - Studebaker - Replaced damaged SW Motech/Twisted Throttle - Installed 06-12.
10. Center Stand Assist Handle - Happy Trails - Installed 05-29-2011.
11. Moose Racing 1" Extended Folding Shift Lever - ProCycle - Installed 05-28-11.
12. Fork Brace - Twisted Throttle - Installed 06-07-11.
13. Dash - Unknown Mfg - small aluminum with lighting and power and LED Battery Monitor - Installed 03-12
14. LED Battery/Voltage Monitor - - Installed in smaller dash - 03-12
15. Tail Box - eBay find - large enough to hold my laptop and some gear - Installed 05-24-11.
16. Aux. Tail Box for "Ready Kit" - Hardigg Storm Case - Installed 05-24-11.
17. Relocate Tag/add LED light - Have Parts - Started on 05-24-11 and Completed (finally) on 07-30-11.
18. Battery Tender/Clothing Whip - Installed by previous owner, good to go.
19. SW-Motech "EVO" Quick Lock Side Carrier - Twisted Throttle - Installed 08-09-11.
20. Ammo Can Panniers - Tough as Nails - Modded and Installed 09-11
21. Tail Rack - JNS Engineering - Installed 5-31-11. (Edit 02-2013 - took off to install rear box).
22. Doo-Hickey - Done 06-24-2011.
23. T-Mod - Done - 08-10-2011.
24. Fan By-Pass Switch and Circuit - Twisted Throttle - Done - 11-19-2011.
25. Replace fuel line - Done - 08-10-2011.
26. Carb Plug Drill and "Kubalink" Mixture Screw upgrade - Done - 07-12.
27. Carb Choke Spacer Replacement - Replace plastic "breakable" one with Aluminum Custom Part - Installed with Harley part #29229-880D for CVK40 Carb (used on Early model Sporsters) - Done - 07-12.
28. UniFilter Swap - Done.
29. Synthetic Oil change-over - Done 05-05-11. (Update - Have been running AMSOIL MC Oil for a year now with great success and 3,000 mile change intervals. Could probably stretch it further, but I'm not that brave.
30. Euro-Control Upgrade for Lighting/Signals - AWESOME !!!! - Done - 05-2012.
31. Upgrade Main Lighting Circuit to work with HID Upgrade/Swap. - Still Shopping/Comparing Kits (07-2012).
32. HID Headlight Upgrade - 35 Watt HID Lamp/Kit - need to order a set - Still Shopping as of 07/2012.
33. Fuse Upgrade and Relocation - Twisted Throttle - Done 11-19-2011.
34. Stainless Front Brake line - "In Hand - need to install (02-12-2013).
35. Stainless Rear Brake line - DONE - 05-12(??)
36. Remove Side-Stand Safety - Done - 08-10-2011.
37. Remove Clutch Safety - Done - 05-12(??).
38. Clutch Arm Mod/Swap - Twin Headlight Ernie Mod - DONE - 01-24-2012.
39. LED Aux. Driving Lights - DONE - 06-2012(??) - Will probably swap these cheap ones out for better ones later.
40. Lower Sub-Frame Bolts Upgrade - Done 05-11-11.
41. Upper Sub-Frame Bolts Upgrade - Done - 05-12 - After breaking one and having to drill through to install new bolt.
42. Upgrade Footpeg Bolts - Done 05-11-11.
43. New Footpegs for better off-road use - Done - 06-12. Used the el-Cheapo eBay pegs and Moose Racing stainless springs.
44. LED Tail Light - Installed 05-05-11.
45. LED Running Lights - Installed 07-30-11.
46. Tool Tube - Re-think and re-design - Installed 08-13-2011.
47. Agri-Tubes for Fuel Bottles/whatever - Installed with Ammo Can Panniers 08-15-2011.
48. Rear Brake Master Cylinder Guard - TCI Prod. - Installed 07-29-2011.
49. Billet Rear Master Cylinder Mount - Happy Trails - Installed 07-29-2011.
50. Front Fender Brace - JNS Products - Installed 07-29-2011.
51. Side Stand Foot Pad - JNS Products - Installed 07-29-2011.
52. Front Fairing Mount Aux. Rack/Brackets/Box/Windshield - TCI Products - Done 11-19-2011 and Removed 12-04-2011; then re-installed partially with LARGE Windscreen in 06/2012 - Thinking about re-installing the rack.
53. Re-Use Front Fairing rack as Tool Kit Mount/Engine Guard - Have Parts - Need to Complete. Changed Plan in 06/2012 to re-use/re-install with new windscreen and maybe use for GoPro Camera Rig.
54. 12V fused rear power source/socket - Installed 07-30-11.
55. Throttle Lock - needed for long-mile slab-bombing - need to pick one and order it.
56. Fuel/Bottle Holders - End of the Road Inc., Quick Fist Mounts - Done and re-used/re-purposed 05/2012-06/2012.
57. LED Dash/Control lamps to replace OEM lamps - Done - 10-09-2011.
58. New Handle Bars - Yeah .. about this line item .. been through two sets (bent) and will probably go through more - DONE - no dates needed.
59. Re-Gear to 16 Front/39 Rear or leave stock 15 Front and go to 40 Rear(?). Still using depending on needs. Using a 14/15/16 front sprocket with Eagle Mike's counter sprocket nut to make changing much simpler. Using a stock rear sprocket again.
60. Leo Vince Silencer - ordered 02-12-2013 from Happy Trails.It's here, waiting on PowerBomb 02-22-13
61. Stainless Header - need to purchase FMF PowerBomb unit - ordered 02-12-2013 from Happy Trails.
62. Moto-Mule Trailer - Got one 02-11-2013.
63. Raising Links - eBay - somehow forgot to add this at some point .. will need to look up date - Done.


"TO DO" List -
1. Re-work electrical and dash to set up as follows:
- a. fused/unswitched "constant on" hardwired mini-usb for GPS unit #1. - DONE.
- b. fused/unswitched "constant on" hardwired mini-usb for GPS unit #2. - DONE.
- c. fused/switched "key controlled" standard 12v power supply on dash. - DONE.
- d. fused/switched "key controlled" std-usb power supply on dash (current one is wired wrong). - DONE.
- e. leave aux LED lighting running off "street lights" supply. - DONE.
- f. leave fused direct-wired std 12v power socket under rear fender/tag. - DONE
- g. install and set up new (louder) horn with relay and heavy-duty power supply.
2. Send off "spare" front wheel/rim to Woody's for a Super Lace and set up for off-road use - build shipping crate.
3. Send off "spare" rear wheel/rim to Woody's for a Super Lace and set up for off-road use - build shipping crate.
4. Move clock to dash and eliminate/replace thermometer .. DONE.
5. Move Tech Mount used for GPS .. it's in the way of the fuel cap. - Removed entirely.
6. Add foam (pipe insulation) to headlight "wall" under fairing .. to block stray light.
7. SuperBright LED lamps to replace all stock turn signal lamps.


Seriously Considering/Possible/Future Farkles/Upgrades/Changes:
01. Faulkner Fuel Tank Mod - Have Parts - Need to complete.
02. 685 Kit - Schnitz Racing - someday .. if for no other reason than to haul all this crap and my fanny around.
03. Front Fork Rebuild/Upgrade - Ricor Intiminators - Have Parts - Need to Complete.
04. Mermite Panniers - Have Parts - Project in Progress.
05. IMS Tank - either the 6.6 or the newer/larger one coming out in Nov. 2011 (and then sell the crash guards?).
06. ALCAN Fairing - have swapped e-mails with Craig Vetter about this new fairing that is under design/development. I WANT ONE!
07. Need to clean out oil strainer/screen - have gasket kit, just need to crack the covers and do the work.
08. 320mm Over-sized Front Brake Rotor - Not ordered yet. - NOT going to do, not off-road friendly.
09. "F-reservoir" for Front Brake Upgrade - Not ordered yet. Not going to do -
10. Replace Radiator with new aluminum unit (slightly larger) and add/mfg. new rock guard for same.
11. New set of plastics for paint/face change to mil. spec. appearance.


Some Things Redone/Rethought and removed or left undone/reversed ..
01. GPS Mount for Magellan Sportrak - RAM Mounts - Installed. - changed GPS units.
02. Pelican 1060 Case for GPS/Whatever - Pelican - Installed 05-24-11. - just to large for cockpit/dash area.
03. Center Stand - SW Motech/Twisted Throttle - Installed 05-11-11. Damaged, Need Repair/Replacement. - Replaced with a much more robust and heavier duty Studebaker rig - the Studebaker is MUCH tougher, but heavier.
04. Dash (changed) - Whitehorse Press "Studebaker" Dash - have parts - building setup. Installed/In-Progress. - To much vibration with the larger dash to the point I removed it. May someday check back into this dash, but not in a hurry.
05. LED Battery/Voltage Monitor (changed) - Twisted Throttle - Ordered 11-05-2011 - will install with (new) dash. Have Parts - Building Setup. - Did not like the part from TT - not waterproof and to hard to read.
06. ThermoBob Mod - not ordered yet (though I did get the overlay for the gauge). Nixxed - just do not need presently.
07. Billet Tensioner - Have Parts - Need to do. - will wait to see if stock part ever needs replacing.
08. Water Bottle Holders - Have Parts - Rethinking this one. - Nixxed - Didn't like the install and found better gear.
09. Britannia Composites LTD. "XS Twin" Fairing - if I can get it in Lime Green .. hopefully. Nixxed - Change of plans/design.
10. MAYBE a steering damper .. don't know that I'll ever need it though .. so it remains a maybe. Nixxed - just not going to need.
11. Carb Re-Jet - Have Parts - Need to Complete. - Nixxed - just don't need to rejet to enjoy with my riding style/use.
12. Carb Needle Upgrade - KLX Needle on Back Order. - Nixxed - shimmed stock needle and runs great!!
13. AirBox Mod with UniFilter plugs - Nixxed - read up on this a little .. don't need to do this mod.
14. Gerbings Temp Controllers - probably the dual set for my vest and gloves. - Nixxed - Using temp-trollers and not planning on permanent installed controllers, ever.
15. "Ghetto Windscreen" - Willson Sperion-Protecto Face Guard installed on stock windscreen - Done - 12-04-2011. - Removed/Nixxed with new windscreen install - 06/2012.
16. "Wheatwacker" Fairing Mod - Shopping for fairing to modify. - Nixxed - I like the new/larger TPI Windscreen and aux. mount.
17. Choke Relocator - Twisted Throttle - Installed 05-05-11. - Nixxed - installed choke/enrichener replacement .. and then had to replace that when it broke with the Harley Sportster Choke Cable.


.. will add/edit as I remember all of the things I have planned and find new ones to add or change up the ideas/installs ..

.. someday I'll edit this list into sections like "engine" - "controls" - "electrical" - "suspension" - etc., etc., ..

Last update: 07/12/2012
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"On the road less traveled there ain't no TP, bring your own and that will make all the difference.."
RevBill's SmugMug Shenanigans
My '06 KLR

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Old 05-24-2011, 04:51 PM   #2
RevBill OP
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.. off to the Nantahala Forest for the weekend ..

.. a few days later I ran across an invite to ride some service roads over in the Nantahala Woods .. what a GREAT weekend .. first time to really find out what my KLR can do .. 75mph on I-40, no problem ..

.. bombing through the woods and gravel roads, no problem ..


.. ahhhhh ... refreshing ..


.. thankfully I had already bought some Barkbusters and had them on for my slide into second base .. nothing like crashing (no sleeping beauty shot though) ..


.. and some JB Weld to put the fairing tabs back on and cable ties for a "good as new" repair .. notice the crash bars, those arrived the day I road out to Nantahala (ahem) .. what timing .. (EDIT on 08-10-11) .. the JB Weld is holding up great on the tabs, but has failed on the lower push-in plugs/mounts .. the tank fairings are (suprisingly) still very solid, but I will be fixing this very soon ..


.. btw .. as of this writing .. one of our fellow inmates owns the Cabins at Nantahala and is probably one of the most gracious and best host (along with his family) that I have met in a long time .. if you have the chance to stay there, do so, you will not be disappointed .. and if he can't go riding with you, he can darn-sure point you to some of the best riding in the area ..
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"On the road less traveled there ain't no TP, bring your own and that will make all the difference.."
RevBill's SmugMug Shenanigans
My '06 KLR

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Old 05-24-2011, 04:58 PM   #3
RevBill OP
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.. out and about .. and a few farkles later ..

.. some farkles have arrived and the 2011 Farkle-fest has begun ..


.. I am really enjoying the KLR .. my poor cruiser may leave me for another man soon .. though she's actually getting stripped down and redone into a mini-dresser ..


.. my kids are diggin the KLR too ..

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"On the road less traveled there ain't no TP, bring your own and that will make all the difference.."
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My '06 KLR

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Old 05-24-2011, 05:02 PM   #4
RevBill OP
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.. starting to play around with some ideas ..

.. moving tag, tail boxes, GPS mount, and much more to come .. I should have posted the Farkle list in the first post .. oh well, I can always edit this later .. (edit) added the Farkle List .. yeesh ..


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"On the road less traveled there ain't no TP, bring your own and that will make all the difference.."
RevBill's SmugMug Shenanigans
My '06 KLR

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Old 05-24-2011, 05:06 PM   #5
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umbrella Corporation FTW!
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Old 05-24-2011, 05:14 PM   #6
Silver King
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umbrella Corporation FTW!

Those guys are jerks.


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Old 01-14-2012, 10:05 AM   #7
eddie bolted
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G]



[COLOR="Cyan"].. btw .. as of this writing .. one of our fellow inmates owns the Cabins at Nantahala and is probably one of the most gracious and best host (along with his family) that I have met in a long time ..
Joe......I met Joe here on ADV and stopped to visit him 2 yrs. ago when i rode to the Smokies! Good Guy.
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Old 02-14-2012, 10:15 PM   #8
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Hi Rev,
That's a nifty little choke unit and thanks for posting up. Very similar to what is stock on the KLX, except if I understand correctly, the position (from open to closed) is variable, whereas the KLX unit is pretty much either open or closed. It won't stay in an in-between position.
Cheers / IDRIDR
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Old 02-18-2012, 11:04 AM   #9
IDRIDR
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Ordered a Raptor petcock yesterday. Thanks fellas!
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Old 05-31-2011, 01:13 PM   #10
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Question You got a PM

RevBill I got a left field question if you could please reply to the pm.
Thank Bud!
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Old 05-31-2011, 05:54 PM   #11
RevBill OP
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.. some thoughts ..

I had a guy ask me about my bike today v my size .. cause I ain't petite and even though the bulk of my riding life prior to now has been Std (Honda CB550 and 750) or a Cruiser (Suzuki VL800 Volusia) it is kinda different to move "down" to a 650 in some peoples minds .. and I even had some trepidation myself, I mean, seriously, when I picked up the KLR I weighed in at about 336lbs .. not small ..

.. so here was my reply .. let me know what you guys/gals with some longer teeth on the KLR think .. tell me if I am wrong or am suffering from some stinkin' thinkin' ..

.. and so .. my reply ..

Good questions all .. no worries .. I have never been petite nor shy about my size .. you're good .. I may even post up my reply on my thread .. here's my seriously long-winded reply ..

.. Keep in mind, I am still learning the KLR myself, but I have met bigger riders than either of us on them too .. so you are in no danger there .. once you set the sag on your suspension you will find the KLR as stable as any bike that tall ..

.. now .. "that tall" .. I also ride a cruiser, and the KLR is NOT in any way a cruiser, but for all of the right reasons .. the biggest adjustment is riding position .. it is top heavy by comparison, but the rake makes the bike much more responsive anyway .. you also need to sit close to the tank (very counter-intuitive for the cruiser-crowd) and that will also lessen your "inseam requirement" .. which is a very easy fix .. you can pick up a used Corbin Dished Saddle (other manufacturers also available) and that will drop you about 2-3" .. and you can pick up lowering links and both a side and center stand that is made for the shorter links as well .. that will solve all of your inseam problems .. I only have a 33-34 inseam at 6' .. little hint, you will absolutely always mount from the left and you will quickly learn to lift your leg and grab your pants cuff and "help" your foot over the saddle .. it's not as awkward as it sounds and is pretty much required for anyone other than Chuck Norris (high kicks), especially when your tail rack is loaded two feet high with gear ..

.. you can spend a fortune on the suspension if you want, but you don't need to .. chances are you won't be competing in the x-games, so you don't need to go nuts right away, if at all .. you can upgrade the rear shock for about 500-700 dollars .. and the front will run you about $150.00 IF (big if) you think you need to .. when I got the KLR I weighed in at 336lbs .. I'm losing weight now though and am down to 285 (or so) .. I also carry a ton of tools, but generally go pretty light on camping gear (oddly enough) .. just crank up the load on the rear shock and if you still need a tad more you can get a progressive spring for the stocker, or for about $200 bucks and a little research you can buy a slightly better one that is a take-off from a military/USMC bike that is rated at something like 550-600lbs (that's my plan btw) .. for the front you just add some (and this is no joke) pieces of 3/4 schedule 40 PVC pipe (from Lowe's or Home Depot) to adjust the sag on the front forks, combined with some fresh #10-weight fork oil and a fork brace .. you will dramatically improve the front end and can remove most of the front end "dive" from hard breaking with a big guys like us on board .. you can also buy a set of the Ricor Intiminators that are reported to greatly help out also .. and I am leaning torward a pari of those eventually as well (but you have to use #5 fork oil with them) .. I have "hit bottom" on my rear shock once catching air off a hill .. but that's because I was sitting the saddle when I landed instead of standing the pegs a little to absorb some of the landing .. didn't hurt the bike one bit ...

.. engine .. unless you got a dog to start with, you can't break it .. I bought mine with 15,700 miles on it and in the past month have already racked up 2000 more .. on trails and over whoop-dee-doos and at 80-85mph on I-40 (which is about full throttle for us big guys) only stopping to fill up the tank every 200 miles .. it's bullet-proof .. and even if you got a dog, there are literally hundreds of after-market sources for rebuilds and Snitz Racing makes an awesome and bullet-proof 685 upgrade/rebuild kit that is almost stupid-affordable .. I plan on upgrading mine even though I don't really need to .. and yes, it will pull a wheely with someone "our size" even without the 685 kit .. and no, I didn't intend to pull a wheely when I did .. lol .. I was trying to merge into traffic .. honest ..

.. after-market "farkles" .. I went with just about everything from Twisted Throttle (SW Motech) .. Happy Trails also has a full line of bolt-ons .. and then the list gets really long for all of the other gear out there for the KLR .. seriously, its amazing how many sources there are ..

.. web support is just as crazy .. seek and ye shall find is just no joke .. and videos to show you how as well .. I've owned a few bikes, never had one with the availability for tech support that is so thorough and so world-wide .. pick a continent and you can find a huge support base and parts, and usually local riders that are also here or on the KLR650 site .. it's pretty damned amazing really ..

.. I spent about three years really digging into KLRs and V-Stroms .. for me the KLR won strictly because my wife prefers the cruiser to ride two-up and there would have been to much over-lap with the V-Strom ..

.. I am also planning a south of the boarder run in the next two years or so .. and I plan on taking this KLR for the trip .. this year is buying the bike and the bolt-ons ... next year I am going to max out the suspension (maybe, I'm really getting pretty happy with a little "spongy" for the service roads and paved roads .. not so sure I want a full-time trail-ready knock-your-teeth-out suspension under my arse for 500+ mile days .. if I don't get crazy ($1000-1500 for the "full monte") on the suspension I may go ahead with the 685 kit (approx. $800-1000 including the motor-work) ..

.. hope some of that helps and I didn't put you to sleep .. lol ..

Ride Blessed,

Bill
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"On the road less traveled there ain't no TP, bring your own and that will make all the difference.."
RevBill's SmugMug Shenanigans
My '06 KLR

RevBill screwed with this post 05-31-2011 at 06:01 PM
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Old 05-31-2011, 05:58 PM   #12
RevBill OP
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.. btw .. that fuel issue I have been having ..

.. anyone chime in here ..

I did some reading and found out that gas issue may be related to the tank vents in the fuel cap .. would never have thought of that .. anyway .. read an old info-gram posted up at KLRWorld (I think it was posted by the late KLRCary) that describes exactly what I am running into with my bike .. and it is dead-bang set on 200-213 miles and I need gas with another 1.5 in the tank .. grrrrrr .. so far I have leaned her over and gotten the gas to get to a station, but dangit "that just ain't right" ..
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"On the road less traveled there ain't no TP, bring your own and that will make all the difference.."
RevBill's SmugMug Shenanigans
My '06 KLR

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Old 05-31-2011, 05:59 PM   #13
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.. hey ..

Quote:
Originally Posted by ggoytia View Post
RevBill I got a left field question if you could please reply to the pm.
Thank Bud!
.. I sent you a reply there .. hope it's what you were asking about .. let me if I got it right or not .. lol ..
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Old 05-31-2011, 06:58 PM   #14
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.. some stuff from today ..

.. never fails .. I start getting ready to go out for the day and ride and the wife pops up with "I need to do a little shopping" .. so off she goes and me and my two favorite mechanics set about to having a little wrench session ..

.. another shot of the Dash ..


.. couple more of the RAM mounts and GPS holders ..



.. and the JNS Engineering Tail Rack ..



.. yeah .. about that tail rack .. some moron (meaning me) decided to cross-thread one of the 6mm screws .. ahem .. luckily the middle right side and not one of the corner mounts .. so .. after the ez-out failed it got drilled out and a 6mm put all the way through with a safety/locking nut .. grrrrr ..

.. may have to wander out tonight though .. just reset the headlight to actually shine on the road when my fanny sits on the bike .. lol .. the PO was much slimmer than me ..
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Old 06-02-2011, 09:07 PM   #15
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RAM locking knobs ..

.. I'll punch up some pics later ..

.. they arrived in the mail .. they are huge and rattle when set to "spin" .. not sure I'll be keeping them or I am going to find a way to quiet them down (rattle) .. kinda annoying really ..
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RevBill's SmugMug Shenanigans
My '06 KLR
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