KLR 650 Modifications

[Aprilia]

Originally Posted by kiln

Is there any riders on the Forum that has an FMF Powerbomb installed and what is the advantages or disadvantages?
Is the mod any good?

I've had one on one of my KLR. Currently run a stock and Leo Vince on two of my KLR's. I ride the KLR's too much to bother with repacking with the FMF. Leo Vince doesn't require it and got tired of the noise of the FMF. Proper jetting and the stock can is surprisingly pretty good. Aftermarket gives you a bit more liveliness with throttle response. Didn't appreciate the backyard solution FMF does to the KLR pipe application for fitment...large dent on inside of pipe. Power bomb is a nice looking header and I never found the need for a heat shield.

[Kawidad]

Originally Posted by Tinker1980

My KLR mods are the following:

Doohickey with torsion spring.
KLX needle
Blue LED's for Dash Backlighting
Milk crate on the rear rack
Happy Trails skid plate
3/16" thick 6061-T6 aluminum bash plate to cover that spot between the bottom of the rad and the top of the HT skidplate. This is a piece I made at work.
1/4" 316L stainless 4.5" lifting links. Another part made at work.

I run a CNC laser burntable, so I can make nearly anything for the KLR, and if I use scrap pieces it doesn't cost anything. My next project will be a chain guide.

Pictures?

[Tinker1980]

Originally Posted by Kawidad

Pictures?

Certainly. It was dark when I made that post, so I took some pictures of my nasty, dirty KLR. There are a couple I forgot to mention, first of which was removing the thing in the exhaust that made it whistle, second the automotive-style horn I installed. The horn is really great, gets more attention than the little "Meep-Meep" horn.

Bash plate:



Lifting Links: (I may make an improved set that are actually dogbone-shaped.)



The whole bike. Such as it is. It's a daily driver though, no matter the weather. I guess I should wash it.

[PWRCRZR]

Originally Posted by Tinker1980

The whole bike. Such as it is. It's a daily driver though, no matter the weather. I guess I should wash it.

Why? Looks good to me

[Boon Booni]

Originally Posted by Tinker1980

I guess I should wash it.

Do you mean your camera lens or the bike?

[RandoCommando]

Originally Posted by Aprilia

I've had one on one of my KLR. Currently run a stock and Leo Vince on two of my KLR's. I ride the KLR's too much to bother with repacking with the FMF. Leo Vince doesn't require it and got tired of the noise of the FMF. Proper jetting and the stock can is surprisingly pretty good. Aftermarket gives you a bit more liveliness with throttle response. Didn't appreciate the backyard solution FMF does to the KLR pipe application for fitment...large dent on inside of pipe. Power bomb is a nice looking header and I never found the need for a heat shield.

I'm glad you brought this up.
I just put the EagleMike jet kit in my KLR with the stock muffler.
Which jet are using for the stock?
Mike suggested I get the Leo Vince slip on, but hell, they are $300 for the X2.
I don't know if there is another slip on by LV or not.
What jetting did you use for the LV?

[RandoCommando]

Originally Posted by Tinker1980

Certainly. It was dark when I made that post, so I took some pictures of my nasty, dirty KLR.

Sorry.
But this is when the KLR is at it's most beautifulness!!!

[Yukoner2]

Being a new KLR owner, where does one buy that classic travel box?

[Aprilia]

Originally Posted by RandoCommando

I'm glad you brought this up.
I just put the EagleMike jet kit in my KLR with the stock muffler.
Which jet are using for the stock?
Mike suggested I get the Leo Vince slip on, but hell, they are $300 for the X2.
I don't know if there is another slip on by LV or not.
What jetting did you use for the LV?

Well, that depends lol. Stock piped bike is kept/ridden at 7000+ft where as the LV piped bike is kept/ridden at 1500+ft. If I kept both at 1500ft and rode just about anywhere I'd probably run the same jetting as I'm more interested in MPG then Peak HP on a KLR. I use/tune with an A/F meter and O2 sensor in exhaust header.

KLX needle - 2nd slot
Main Jet - 140
Pilot Jet - Stock
Fuel Screw - Adjust for A/F of 13.1 or in your case best RPM's. If you don't have an adjustable screw figure around 2 turns out
Snorkle - Pulled
Slide vac hole - Drill to 7/64ths

Figure you'll get 46-50mpg in mixed riding with the above setup. If you want best HP with aftermarket exhaust go with 142 main jet. On a few modified KLR's I've sniffed a couple wanted the needle set to slot 2.5. Do so by adding a shim under the clip to split the difference between slot 2 and slot 3. I have yet to sniff ANY KLR engine that needed anything larger than a 142 main jet and that includes 4 engines with 705 kits and larger valves. All were still running stock cams and timing so might be different with aftermarket cams or altered cam timing.

LV only has the one slip on for the KLR.

Current project is finishing up FI with closed loop software for the KLR.

[Rev]

Originally Posted by Yukoner2

Being a new KLR owner, where does one buy that classic travel box?

buy?

[Tinker1980]

Originally Posted by Yukoner2

Being a new KLR owner, where does one buy that classic travel box?

A guy at work had about a half dozen of them in his truck, said he was tossing them and would I like one. For the cost of a handful of M6x1.0 bolts (Which I think I had on hand anyway, because I never toss bolts that are in good shape) I had a great box. Not only can you put stuff in it, but you can strap things to the outside of it as well.

Boon Booni, I should probably clean both. The camera lens gets dirty cause it's my cellphone camera, and the otter box saves the actual lens from the dust/areosolized steel present where I work. But that lens protector has seen better days. As for cleaning the KLR, I worry that if I wash it the oil won't stay in it.

[GAS GUY]

Has anyone seen or tried these yet by Stead Engineering ?
These look really nice for anyone wanting to get rid of the cable and the cheap plastic nut.

http://www.steadengineering.com/prod...2&categoryId=1

[Marty 650]

Picked up black/ smoked turns signals for $30.00 at Cycle gear. Going with the next size up for the rear.
Fits the 05 fairing well and looks sharp!
I'm a noob, so not sure how to attach pics..??

[IDRIDR]

Originally Posted by GAS GUY

Has anyone seen or tried these yet by Stead Engineering ?
These look really nice for anyone wanting to get rid of the cable and the cheap plastic nut.

http://www.steadengineering.com/prod...2&categoryId=1

And there's a similar one on fleabay for the same price, but it is friction actuated so will stay in partial open (unlike my KLX250 choke pull). I've seen positive reports here on the fleabay one.

[PWRCRZR]

Since I have decided that I do not want to part with the money to buy a new bike to replace the KLR anytime soon. And that quite honestly the KLR has become part of me and I really do enjoy riding it. I figure it is time to give it some attention this year.



The bike is getting close to 25,000 miles and burns little oil.
Yes the doo is done as well as many other things.

Maintenance plans..
Service the forks and shock, both were upgraded and done several years ago.
Check head bearings, swingarm bearings and both wheels.
Check and repair electrical system, side stand switch acts up from time to time as well as the clutch safety switch.

I am also considering doing the 685 kit to freshen up the motor and rumor has it maybe smooth it out a tad. I am also considering a leo vince exhaust.

Clean and rejet carb if needed.

I already opened the air box a bit and changed to a uni filter.

I also have plans to pull my crash bars skid plate and racks to go over my crappy welds as needed and possibly powder coat.

There is an endless list of little things that need cleaning and repairs but most are minor or cosmetic.

If anyone has any suggestions on things I should check or thoughts on weather I should do the 685 kit lets here them.