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Old 06-03-2013, 05:38 PM   #46
Hondo OP
What if its a Samsquamch?
 
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Joined: Aug 2006
Location: Denver, Colorado
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I just took the KLX450R for it's first real test offroad- the White Rim Trail in Moab, Utah-

Ride Report HERE



The bike was fantastic!
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Hondo screwed with this post 06-11-2013 at 07:34 AM
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Old 06-03-2013, 07:22 PM   #47
Coachgeo
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Much Congratulations. Bet it felt good after all the work for it to work so well for you!
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Old 06-04-2013, 11:12 AM   #48
Dirigo
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Thanks for a great write up Hondo! I really enjoyed the read!
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Old 06-05-2013, 02:08 PM   #49
BigDave75
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Great Job Hondo, that is a beautiful build!
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Old 07-15-2013, 09:04 PM   #50
GZERO
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Great job!
nice build.
The Klx has a few things you need to keep an eye to, but just for once.
If you remove your stator cover, remove the flywheel you'll find an oil pump screen that sometimes it gets a few silicon remainings. Take it apart and check it. you need to check this just once.
Also, since intake valves al Titanium, keep an eye on them. When they start to move buy kibblewhite (spel?) and turn them to SS.
The stock KLX engine can go many hours without taking it apart.
But, like i said, if the valves start to move, take it apart, don't wait till it destructs itself.
What did you do with you jetting? (mine is spot on with my mods)
I use my KLX450 in some gnarly (1st and 2nd gear) trails near my house and i have found that the cooling system has no flaws in my case (note that i live in venezuela and temps here are almost always above 100 when i ride)

I'm a bike mechanic soo feel free to shot me a pm.
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Old 07-16-2013, 07:51 AM   #51
Hondo OP
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Thanks for the tips- I will look at the oil screen & the valves soon.

I'm using a JD Jetting Kit. The previous owner had it installed & the bike is great at altitude(been to 13,000 without issue.
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Old 07-17-2013, 08:44 PM   #52
Hondo OP
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Today I serviced the forks as I had no idea the quantity or quality of the fork oil.

I needed 2 special tools for the job- a 49 mm cap wrench and a 14mm hex driver.

I picked up a Motion Pro 49mm Dual Chamber Fork Cap Wrench locally-



I also picked up some Belray 5W fork oil.

I looked at Sears for the 14mm hex head driver (to go on a socket wrench) but they didn't have one in the store.

So I bought a set from Harbor Freight for $13.00-



Here is one of the forks being disassembled on the bench-



Not a difficult job by any means, but oily/messy and ya gotta keep everything clean.

The oil looked thick & had various shades of green, so it was probably the original 2008 fork oil.

I'll be testing the bike tomorrow -
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Hondo screwed with this post 10-27-2013 at 08:14 AM
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Old 07-20-2013, 04:03 PM   #53
Bird76Mojo
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From what little I've read, the valves in the KLX are steel.



Quote:
Originally Posted by GZERO View Post
Great job!
nice build.
The Klx has a few things you need to keep an eye to, but just for once.
If you remove your stator cover, remove the flywheel you'll find an oil pump screen that sometimes it gets a few silicon remainings. Take it apart and check it. you need to check this just once.
Also, since intake valves al Titanium, keep an eye on them. When they start to move buy kibblewhite (spel?) and turn them to SS.
The stock KLX engine can go many hours without taking it apart.
But, like i said, if the valves start to move, take it apart, don't wait till it destructs itself.
What did you do with you jetting? (mine is spot on with my mods)
I use my KLX450 in some gnarly (1st and 2nd gear) trails near my house and i have found that the cooling system has no flaws in my case (note that i live in venezuela and temps here are almost always above 100 when i ride)

I'm a bike mechanic soo feel free to shot me a pm.
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Old 07-20-2013, 06:33 PM   #54
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Keep This Going

Great write up. I like the way you do things. Top notch! Thinking now of ridding myself from my current ride (2003 Vstrom 1000) and going along your same lines. Great photo work as well.
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Old 07-20-2013, 07:45 PM   #55
Hondo OP
What if its a Samsquamch?
 
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Quote:
Originally Posted by Scubawerx View Post
Great write up. I like the way you do things. Top notch! Thinking now of ridding myself from my current ride (2003 Vstrom 1000) and going along your same lines. Great photo work as well.
Glad you like the build!

One thing to remember about the KLX450R & most of the other 450 cc bikes- they are really high strung off road bikes that can be dual sported, but they need to be treated somewhat like race bikes.

I have my KLX450R as my dedicated trail bike, and being street legal, I can connect trails & passes here in Colorado with ease. But it's not like a KLR650/DR650- those bikes are made to cruise all day on the freeway. The 450s can go there, but with little more than a quart of oil and no thermostat (mine will be getting an inline thermostat soon) they really are not good for long hauling.
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Old 07-29-2013, 12:03 PM   #56
Hondo OP
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RMAR Update-

I just returned from the 2013 RMAR gathering in Silverton, Colorado.

Before I left I installed a Dunlop D606 front and Michilen MT43 rear tires. I also softened up the suspension ( rebound & compression damping settings ) to deal with the rocky terrain.

While there I rode the KLX450R VERY hard over Cinnamon, Engineer, California, Hurricane, Corkscrew, Black Bear, Imogene, and Stoney passes.

The bike was awesome!

But, wanting to improve the low & mid powerband and to make oil changes easier (the stock exhaust header blocks the oil filter) I ordered a FMF Powerbomd Exhaust pipe-



I'll post up some pics of the install when it arrives-
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Old 07-29-2013, 04:07 PM   #57
Hondo OP
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Atop Imogene Pass, Colorado this past weekend-

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Old 08-03-2013, 04:01 PM   #58
Hondo OP
What if its a Samsquamch?
 
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I just finished installing the FMF PowerBomb header pipe- a relatively easy job.

Of course it wouldn't be a "custom" motorcycle if there wasn't any install mods necessary now & again. The graphite seal between the header pipe and the muffler was too thick internally (the FMF pipe would not slip into the seal). So I had to unravel the seal until it would fit.

Here's the PowerBomb next to the stock KLX450R header -



Here is the stock KLX450R header installed- notice that it blocks the oil filter cover (makes changing the oil a PITA) -



Here's the bike with the PowerBomb exhaust installed - hey, you can see the oil filter access!



I rode it around the block & all I can say for sure is that it doesn't leak and the tone seems a bit deeper.
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Hondo screwed with this post 08-03-2013 at 04:58 PM
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Old 08-09-2013, 10:27 PM   #59
NSFW
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hondo, looking good. great job. you're a one man, do it all shop.

looks like you had a great time at rmar. i didn't go but i will be at the ktm rally at steamboat springs. hope to see you there.


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Old 08-09-2013, 11:00 PM   #60
Hondo OP
What if its a Samsquamch?
 
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Quote:
Originally Posted by NSFW View Post
hondo, looking good. great job. you're a one man, do it all shop.

looks like you had a great time at rmar. i didn't go but i will be at the ktm rally at steamboat springs. hope to see you there.


Thanks J!

We were wondering if you were attending this year, but we never saw you.

Maybe next year!
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