KLR 650 Modifications

[DirtyDog]

Originally Posted by tommu56

What is the ID of the hole for the spring compressor and the over all length?
I'd like to copy it if you don't mind


tom

The hole is not perfectly round, but my best measurement puts it at 72mm diameter.

The overall length is about 178mm.

For safety reasons, don't skimp on the material. A compressed spring could be dangerous.

[Lornce]

Excellent post.

Originally Posted by DirtyDog

Today was the culmination of my stock shock rebuild.

Originally began HERE.

So my parts arrived a few days ago, and I got to reassembly yesterday with an onlooking inmate JumpJet enjoying a cold beer.

I was doing a final cleaning of all the shock parts including a light sanding with some 400 grit paper (mostly on the outside of the shock reservoir tube. I noticed that the piston shaft had some pretty significant wear on it. I tried my damndest, but this is the best pic I could get.



When running my finger over the wear area, it was clear that this weasn't gonna work. The area was about 1.5 inches in length and would probably result in a rapidly failing seal.

Ok, guess I need to go to plan B. I have a second shock on the bike, so I got to removing that one to see if rebuilding it would be a better option. It was.

Of course, I had to remove the progressive spring. Good excuse to use the Throttlemeister Spring Squisher 3000. Hopefully, it is self-explanatory.



This shock had fewer miles on it and though it too had a visible wear area, it was nowhere near the size and extremity as the original shock. Couldn't really feel it when running a finger over it.



The inside of the tube was smoother on shock #2 as well, so I used all parts from the second shock for the rebuild.

First part to go on the rebuilt shock is a new bumper. Something is off here...


Since I wasn't interested in reducing my shock travel any more than stock, I trimmed down the bumper with a razorblade to match the stock height.

Next, I installed the new seal head with new o-ring. The piston o-ring they sent appeared way too small (mistake?), so I just re-used the one already on there. It still had a crown on it, unlike the squared-off one on the other shock. This isnt the part that keeps the oil in the shock anyhow, so I felt it was of less importance than the seal head.

Reassembled the shock fully, as per the instructions and filled it with 130cc of 3wt shock oil (from MotorcycleSuperstore). I used a 10cc syringe with some air tubing while the shock was clamped upright in a vise.

Reinstalled the schrader valve and gently warmed the shock with a propane torch to get all the air up top where it belongs. Then I purged the air by squishing the shock until oil came out. Did this several times just to be sure.

My buddy _cy_ came over with a nitrogen tank and we added 150psi. Put the spring back on, and voila... we have a rebuilt shock for very little $.



Easy project. Minimal cost. I think anyone with an ounce of sense (and coordination) could probably do this.

Some things I learned along the way... "tips" if you will...
1. There are two holes in the shock tube cap. These holes facilitate removal, but they also allow grit to get in there with the seal head. I plan to fill these holes with silicone to help prevent this.
2. When removing the massive stack of shims, washers, etc. from the piston, place a ziptie in the hole of the piston shaft and remove the shim stack as one unit, threading it right on to the zip tie. Close the zip tie and don't open it until you go to reinstall, reversing the process. No worries about the order or configuration of all those shims.
3. The spring has to be removed to do the air purging and nitrogen fill. I got ahead of myself and fully reassembled a bit to early. If installing/ removing the spring weren't so easy with the Throttlemeister Spring Squisher 3000, it would have been a PITA.
4. Make sure that before you reinstall the spring and mount the shock, confirm the preload and rebound adjustments are facing opposite ways. I did this by dumb luck, and it would have been a PITA to discover this later.

If I think of anything else, I'll update here...

[PWRCRZR]

agreed...very good post Thanks for sharing, especially the tip on the spring compressor

[Tsotsie]

Originally Posted by PWRCRZR

agreed...very good post Thanks for sharing, especially the tip on the spring compressor

+1. It will be interesting to see how long the replacement seals last on the worn rods.

One reason I went for the CD Moab shock several years ago is the $75 'tune-up' every 15K+ miles he offers to replace wear items to the original buyer.

Tell us more on the gas pressurization.

[DirtyDog]

Originally Posted by Tsotsie

+1. It will be interesting to see how long the replacement seals last on the worn rods.

One reason I went for the CD Moab shock several years ago is the $75 'tune-up' every 15K+ miles he offers to replace wear items to the original buyer.

Tell us more on the gas pressurization.

The pressurization took all of 1 second.

Nitrogen tank with a 2 stage regulator set to 150psi. Used a basic double-sided air chuck (like you use for tires).

I clamped the shock vertically in the vise. Purged the air as described above while pressing the valve core. Release it when oil comes out.

Then add nitrogen. Small volume, so it fills instantaneously.

[Aprilia]

Originally Posted by Sludminger

I just picked up an '09 KLR and am ready to get on the farkles. I'm 6'5" and am looking for tall guy specific recommendations, specifically:

• parts to lower the foot pegs (I haven't located any yet)
• bar risers (interested in the 2" pivot style ones from KLR 650.com)
• windscreen (interested in the MRA Vario Touring Screen with the adj spoiler, but read a review that there's a lot of bufetting with taller guys)
• seat (I'm realizing that the hump for the passenger in the stock seat is a little too far forward)

I'm looking to set this bike up for more dual-sport type adventures... more dirt... less road!

* I wouldn't lower the pegs. They are low enough already and in particular with 2nd gen KLR
*Rox risers are very nice. I went with 1" risers I had on hand.
*Left the stock windshield
*I added nearly 2" to my seat as well as widen it 2". Good for 300 mile days. For aftermarket Seat Concepts will custom one for you.
*Biggest improvement was switching to a Henry/Reed bar. Us tall guys need a bar with very little pull back for standing.

[Mile Maker]

Originally Posted by Aprilia

* I wouldn't lower the pegs. They are low enough already and in particular with 2nd gen KLR
*Rox risers are very nice. I went with 1" risers I had on hand.
*Left the stock windshield
*I added nearly 2" to my seat as well as widen it 2". Good for 300 mile days. For aftermarket Seat Concepts will custom one for you.
*Biggest improvement was switching to a Henry/Reed bar. Us tall guys need a bar with very little pull back for standing.

+ 1 for the Rox risers. I went with the pivoting anti vibe units, The bike is now very comfortable to ride long distances. less handlebar vibrations plus better ergonomics.
Ive tried a couple of different windshield combinations, none have worked so far. i tried the kawi tall, and tried a laminar lip configuration. Always ended up with terrible buffeting. I'm 6' 3"
I want to try the cee bailey windshield eventually, but for now i will just live with cleaning the bugs off of the visor.

[Dusty_Bottoms]

Originally Posted by Mile Maker

+ 1 for the Rox risers. I went with the pivoting anti vibe units, The bike is now very comfortable to ride long distances. less handlebar vibrations plus better ergonomics.
Ive tried a couple of different windshield combinations, none have worked so far. i tried the kawi tall, and tried a laminar lip configuration. Always ended up with terrible buffeting. I'm 6' 3"
I want to try the cee bailey windshield eventually, but for now i will just live with cleaning the bugs off of the visor.

I've tried many many windshields and combinations of laminar lips and am currently running the tallest CeeBaileys windshield and it's the worst buffeting so far. I'm six one. I'm going back to no windscreen probably.

[uxorious]

I'm 6'1" with a 34" inseam. I went to Laminar Lip with minimal improvement. Next was a Madstad windscreen and adjustable bracket. A bit of trial and error to get it in the best position but it's a miracle. A quiet air pocket and visor up all the time.

[Mile Maker]

Originally Posted by Dusty_Bottoms

I've tried many many windshields and combinations of laminar lips and am currently running the tallest CeeBaileys windshield and it's the worst buffeting so far. I'm six one. I'm going back to no windscreen probably.

Does your cee bailey have the adjustable bracket? New style or old style KLR? i have an 09.
i will have to check out the Madstad windscreen as well.

[Dusty_Bottoms]

Originally Posted by Mile Maker

Does your cee bailey have the adjustable bracket? New style or old style KLR? i have an 09.
i will have to check out the Madstad windscreen as well.

old style KLR, no adjustable bracket
I wish I could try the madstad for less than $280!

[Hillbillyburg]

Originally Posted by Dusty_Bottoms

I've tried many many windshields and combinations of laminar lips and am currently running the tallest CeeBaileys windshield and it's the worst buffeting so far. I'm six one. I'm going back to no windscreen probably.

I'm 6'3 with a 2" Rox riser and Protaper ATV high bend bar so my riding style is pretty upright. I have the KLR Dash with a Zero Gravity Sport Touring windshield on risers. The wind travels 1" over my Hornet helmet. Awesome set up for a few bucks. Some people don't like the looks but I actually like the funtionality and it does kinda mean up the bike a bit.

Tip: Order the Zero Gravity on the KLR Dash website with the risers and they will cut it down for free and supply a rubber molding to finish off the windshield.

[Snypercell]

So....It was raining all day today, so I took a little trip to Lowe's this a.m.

Like you guys, I hate that wind buffeting with a passion. I'm 6'3", and it slaps me right in the eyeballs.... I don't mind wind one bit. I rode with the entire fairing off for a while (had a homemade headlight rig that seemed to work pretty well), and I've tried the fairing without the windshield, both of which are major improvements over the stock setup. Fresh Air > Buffeting in the Face. Finally, I decided it was time for the Wheatwhacker mod.


I put some longer screws towards the top, so that I can use them later to help installing the dash, gps mount, and such. I bought a piece of $2 1/4" plexi glass while at Lowe's, so I can carve me up a dashboard.


I got it all fixed up and took it for a spin. I'm still getting the buffeting right in my face, but there is DEFINITELY a larger calm air cavity forward of me. If I had the highway pegs and could sit down a little, or had a tank bag and could lean forward a little, it would be the best so far. If only I could find a British Composites for the cheap....


I spent all day "whacking" my fairing up, while I was at it I shortened up my clutch and brake levers with the trusty Dremel. VAST improvement. Seeing as how there are no aftermarket, dirt bike style levers for the KLR.



I am about to order the Lexx exhaust for $178 off of ebay, can't find a better deal, I think. So... while I was in the garage, I started the Frugal mod. No more tweet!! And Oh my!!! does this sound nice! It was 1am when I got everything buttoned up, so I didn't rev her or take her around the block, but I like it. Almost enough to just order a cap, and all it good.


My tool tube, in the works.

[RandoCommando]

Originally Posted by Snypercell

My tool tube, in the works.

That's one big ass tool tube.
I've never seen a dog fit his entire head in one!

[Snypercell]

Originally Posted by RandoCommando

That's one big ass tool tube.
I've never seen a dog fit his entire head in one!

Hahahaha!!!

I want to get him a side car. He wants to ride so bad....