another versys powered klr

well here it goes guys another versys powered klr project. mostly because i saw a complete versys partout and couldn't pass up the deal and the proximity.

Here's the frame.


and the engine.


everyone knows it doesn't fit in. i plan on copying some of klrsys project because its the most well documented and makes sense to me as well.

first thing's first, flip those carb boots


their directional which is why you have to flip the carbs as well


that's it for now. time to get out the sawzall

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Cool project!! I know this has been done before but never looked at a build. What fuel tank are you going to run? Just wondering about the fuel pump.

Im basing most of my project on klrsys's build thread. He ran the stock tank and rigged it so the hose ran into an external fuel pump mounted under the seat. I'm looking at the fuel pump and figuring out my options but that looks like the simplest way currently.

I was goiing to put a ninja motor in crf 450 frame but the fuel pump worried me. Will the fuel pump be submerged in fuel because thats what keeps the pump cool and with a external fuel pump you have to think safety. I was thinking about a fuel tank off a 610 husky but don't know that would work. Would have to compare fuel pumps. Will be watching.

The stock Versys fuel pump has to be put in a can for cooling. If anyone knows of a suitable small external pump and regulator I would like to hear about it and I'm sure Tom would also. The specs for the stock pump:

With engine idleing: 294 kPa (3.0 kgf/cm2, 43psi) with fuel pump running
Discharge: 60ml or more for 3 seconds (72 liters/hr)

The Suzuki LT-R 450 quad pump is perfect. It's about 4-5" long and should put out enough juice for 65 RWHP.

The problem with an external pump is the fuel lines. If you was to wreck and break or crack a fuel line with that much fuel pressure it could be bad real bad.

I don't really get the concern?

The pump and lines would be tucked in under the tank, so they won't be damaged if you crash. If you use fuel injection rated hose it will not split either.

And most importantly, the only difference between internal and external pump is the line going from the tank to the pump, and that is not even under pressure?

The stock line thats under pressure on the ninja is very short when you move it under the seat you will have two long fuel lines. This bike should be able to run over 120 mph. It just scares me not saying it wouldn't work. The tank off of a KTM or Husky that has the fuel pump in it would work and be safer and easier. Just my opinion.

You sleep with the lights on don't you.

I've worked on a few bikes that had external pumps, never heard of them turning into fire balls.

Like that other guy said, the only difference would be a couple of inches of plain rubber fuel line from the tank to the pump, even mounted under the seat the bike would have to turn itself inside out for damage to occur.

Facet makes some really nice, small external fuel pumps. They are a common upgrade on KTM Adventures. DAMHIK.

As an example:

http://www.aircraftspruce.com/menus/ep/fuelpumps_0facetelectric.html

FAA rated, so....................

BTW, since you have a bare KLR frame, I would suggest welding a small plate over the spine above the shock mount/down tube area. There is a lot of stress on that point is it is known to fail and be a weak point.

I'm in.

service manual reveals fuel pressure is 294kPa, 41.81psi and discharge is 83mL (2.8US oz) and more/10 sec. i dont think it will work with that lower flow rate, anyone else know if it would or wouldn't?

What about the ninja fuel pump?

It would with a regulator, your local autoparts store should have a couple of aftermarket performance brand fuel pumps sitting on the shelf as well.

When I replaced the 3psi stock fuel pump on my royal star venture I found a mr. gasket pump at autozone for a whole $15, the stock was remote as well and retails for $145.

Great project. Good luck.

oops



and all done with a handsaw because i'm cheap like that!

Been there and done that on my old yamaha AT1, your going to look like a fiddler crab by the time this build is done lol.