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Old 08-23-2008, 02:04 PM   #76
SATEX
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Quote:
Originally Posted by tonymorr
Nuh ah, loud pipes save lives baby!

Yes, I am putting a silencer back on. I'm going to put the stocker back on for now so I can ride it. The stock can has got to weigh 20 lbs. I'm not kidding, it's crazy heavy. I want to get the exhaust out from underneath the bike. I was thinking a low, side exit carbon fiber two brothers. Anyone know a good custom exhaust shop? I also want to modify the oil pan so the drain plug isn't as low. I think it just sticks down like that so it's easier to drain when the plastics are on. Imagine a bike manufacturer making it easy to change the oil!
Actually, it WAS a silly question....I assumed you'd tend to the exhaust, but was curious about how. I think the Versys/Ninja has two key areas that MUST be addressed prior to even considering dual sport duty.

You've done the front end/wheel, which is one. The low exhaust is another. That's probably easier to attack than the front wheel, because you have plenty of room to be creative. I imagine that an upswept exhaust pipe with a can on one side just behind a side panel would work best. The trick will be getting the pipe bent to the correct angles, and then getting a suitable silencer. Mounting the silencer will require welding at least one tab on the frame. Also, you might have to do without a side panel, which may be no biggie if you're planning using Pelican bags.

Frankly, I'm ambivalent about the passenger pegs. I do think a third issue to consider is lengthening the rear suspension. I don't know if the frame geometry would allow that, and then if it's possible to get a different shock setup that would work. The stock rear suspension wouldn't keep me away from riding it like a dual sport, but it would impact how I could ride it and to some extent, where.

Regarding the oil drain plug, wouldn't the Happy Trails skid plate protect that? I'd want a skid plate for dual sport use anyway, so if that does work I'd just declare victory and move on.

Anyway, congrats again for the great work. I look forward to the next update.

We'll look forward to your next update.
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Old 08-24-2008, 08:23 AM   #77
tonymorr OP
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Maiden voyage

So, I got all the loose ends tied up enough so I could ride last night about 9:30. Just rode it into Saratoga and then to a freinds house. Adjusted the bars and levers a few times. What a hoot! Here's some pics. Remember.....it's not done yet.







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Old 08-24-2008, 05:02 PM   #78
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What do you plan to do for the front brakes? Nice work.
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Old 08-24-2008, 06:12 PM   #79
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Wow... I mean WOW!!! Someone at Kawasaki corporate really needs to see that bike. They have the parts literally in the bins to build it tomorrow.

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Old 08-24-2008, 06:57 PM   #80
tonymorr OP
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Quote:
Originally Posted by llamapacker
What do you plan to do for the front brakes? Nice work.
Using the '08 KLR caliper. The KLR uses a 280mm rotor. I'm going to use an '03 SV650 rotor. It's 290mm so I may have to turn a little off the O.D. The offset (none) seems to be right. I found one, it's in the mail.

P.S. Yes I'm going with a single disc. It works on the KLR.
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Old 08-25-2008, 08:41 AM   #81
clapped_r6
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Awesome work. This is what Kawi should be building.

Although with a high pipe and a recessed drain plug.

Keep it coming!
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Old 08-25-2008, 08:47 AM   #82
lonewolf121
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I've been watching the work you have done on your bike; but came to have a peak after your recent post in another forum. Man that thing is looking sweet!

lonewolf121 screwed with this post 08-25-2008 at 12:20 PM
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Old 08-25-2008, 11:03 AM   #83
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Adventure is taking inappropriate equipment to out of the way places.
Nice job. Good to know I am not the only guy putting a street bike out on the trail.
(Buell XB9SX CityX)
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Old 08-25-2008, 11:48 PM   #84
Wayne Weber
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Quote:
Originally Posted by tonymorr



Hey that's pretty cool! It will never be "done", sorry man! You've made the leap into custom ADVbikes.

If it was mine I'd think about barkbusters and a seat that lets you move around more. Well, and a front brake but you're working on that.
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Old 08-26-2008, 02:40 AM   #85
EvilClown
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Cool! Can't wait to see it in person at Cromag.
Quote:
Originally Posted by tonymorr
Using the '08 KLR caliper. The KLR uses a 280mm rotor. I'm going to use an '03 SV650 rotor. It's 290mm so I may have to turn a little off the O.D. The offset (none) seems to be right. I found one, it's in the mail.

P.S. Yes I'm going with a single disc. It works on the KLR.
PS - Please define works. Maybe the '08 does but the earlier models - even with the upgraded rotor - is frightening at times.

Nice work, though. It's been fun to follow along.
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Old 08-26-2008, 09:25 AM   #86
dancolin
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Tony, that beast looks cool!! cant wait to see it in person. awesome work!
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Old 08-27-2008, 08:21 AM   #87
FloridaSteve
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This bike has really gotten to me. I assume you could use the KLR spoked wheel (or lace up whatever sized rim to the KLR hub). Is there a spoked hub option that might work for the rear?
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Old 08-27-2008, 08:29 AM   #88
tonymorr OP
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Quote:
Originally Posted by Wayne Weber
Hey that's pretty cool! It will never be "done", sorry man! You've made the leap into custom ADVbikes.

If it was mine I'd think about barkbusters and a seat that lets you move around more. Well, and a front brake but you're working on that.
Thanks Wayne.

Sorry I haven't sat down and done a report yet. I can tell you that I'm very happy with the power even with the stock gearing. It feels like a 650 thumper at low rpms but keeps on pulling. I have a friend that has been busting on me since I started working on it saying "Just buy an orange bike and be done with it". I think he actually used the word stupid when talking about my project. Well his place was one one of the first stops I made. He liked the way it looked right away and then took it for a ride. He was impressed and said it was a hoot. He really didn't want to like it but he couldn't help himself. I was nervous as I watched him do a couple of wheelies back and forth in front of his house. (Still with no front brake) I know they don't work in the air but you do have to stop eventually

Anywho, here's a short and long list of things that I still want to do....

SHORT LIST:

1.'08 KLR 650 front fender.

2.Buell dual round headlight.

3.MRA Speedscreen.

3.Cycra or Weestrom handguards.

4.Radiator guard.

5.SW Motech crash bars.

6.Skidplate.

7.Steering stabilzer.

8.Mount my Stormcases.(Like Pelicans)

9.Vario adjustable footpegs

LONG LIST(winter):

1.Wilbers shock to raise the back 1" and give a better ride.

2.Lower the forks in the triples when I install the shock to maintain my 28 degree rake angle.

3.Racetech cartridge emulators and springs.

4.Reroute the exhaust to right side of oil pan and out the back with a low carbon fiber can.

5.Cut the drainplug boss on the bottom of the oil pan and make it tighter to the engine so it is less vulnerable.

6.Alpina tubeless spoked wheels.
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Old 08-27-2008, 08:41 AM   #89
tonymorr OP
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Quote:
Originally Posted by FloridaSteve
This bike has really gotten to me. I assume you could use the KLR spoked wheel (or lace up whatever sized rim to the KLR hub). Is there a spoked hub option that might work for the rear?
I haven't looked into it yet. Tubeless is more important to me than spokes but I would really like both tubeless and spoked! The Italian wheel company Alpina has a tubeless spoked system that the supermoto racers have been using for a few years. KTM has a set in their hardparts catalog for supermoto. Alpina seems very slow to expand their products. They have a kit listed in their '08 catalog for the 950 KTM but noone here in the States has gotten back to me with info. They say it's hard to get the info from Alpina. I gave up for now.
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Old 08-28-2008, 01:25 PM   #90
tonymorr OP
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I got the front rotor on. Much more fun to ride with both brakes!

I weighed it too.

399 lbs with the tank empty
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