Project Bike Kawasaki EX500 + KLR

R'oli · 04-28-2013, 09:39 AM

I have an EX500 coming my way, I have heard a KLR 650 front end and rear end will strap right on, does anyone have any experience with this, or know where I could find out if this is true?

Beezer · 04-28-2013, 11:39 AM

don't know if that is true. look up the KLE500 (available in Europe). it's the ds version using that engine as a base. it had different cams, etc to move the power band down. it was on my list to build one.... might still. it would be cool if there were bolt ons. can't imagine that it would be too hard to adapt something.... if it came to that the klr front end would not be 1st choice

R'oli · 04-28-2013, 08:23 PM

Breezer,
Only reason the KLR front end is I may have one available.

It will be a Frankenbike, I don't want to spend a tonne of money or I'd go buy something else.

Any suggestions would be appreciated.

Beezer · 04-28-2013, 10:52 PM

Ricor valves in the klr forks work wonders.... I have 'em in mine. if I was going from scratch I might choose something better, but if you already have them they can be made decent. I have many years on klr's, contact me if you go that way, there are a couple tricks even if you stay stock

R'oli · 04-29-2013, 01:48 PM

Breezer,
that would be great, picking up the EX this week and awaiting reply from KLR owner, engine blown and wants to part it out. But if there are other options I am interested in hearing all you have to contribute. I don't want to buy the KLR parts if they are not a fit, require extensive mods, or there are better options.

dbarale · 04-29-2013, 03:24 PM

Quote:

Originally Posted by R'oli

Breezer,
that would be great, picking up the EX this week and awaiting reply from KLR owner, engine blown and wants to part it out. But if there are other options I am interested in hearing all you have to contribute. I don't want to buy the KLR parts if they are not a fit, require extensive mods, or there are better options.

Fitting the EX engine in the KLR frame would make a pretty good ADV bike...

R'oli · 05-02-2013, 05:21 PM

Internal of tank is in bad condition, any suggestions on liner products?

sailah · 05-02-2013, 05:27 PM

Quote:

Originally Posted by R'oli

Internal of tank is in bad condition, any suggestions on liner products?

POR15 cycle tank liner kit. Follow the instructions EXACTLY.

http://www.amazon.com/POR-15-Cycle-T...ank+repair+kit

ban · 05-02-2013, 06:12 PM

http://advrider.com/forums/showthread.php?t=741790

yokesman · 05-03-2013, 06:39 AM

there is also the kle 500 that the rest of the world gets ,a quick check on the net brought up only an italian forums site but many reviews and comments like"how come my kle500 handles better than my gs.?"
a high end builder uses that engine for their RTW bike.

dakman74 · 05-03-2013, 09:11 AM

Quote:

Originally Posted by R'oli

Internal of tank is in bad condition, any suggestions on liner products?

http://www.kbs-coatings.com/tank-sealers.html

Not a one-step and done type of thing, but the kit comes complete with the cleaner, rust-converter, and sealer, plus instructions and tips on how to do it properly. The hardest part for me was the sealing process since my tank didn't allow for drainage of the excess sealant so I had to spend about 4 hours of going out at different intervals and rolling the sealant around until it stopped flowing.

It should be cured today, and from what I've seen so far, it's looking like it's gonna last. I've read on other forums and have heard from hotrodders and Jeepers that this stuff works a LOT better with high-ethanol content fuels than some of the other products.

http://www.hirschauto.com/prodinfo.asp?number=ARK-01

Some have used those on tanks, but I've heard that because it dries so hard that with vibration it tends to break up.

http://damonq.com/Red-Kote.html

More guys swear by that one, and supposedly it remains flexible like the KBS coating. The downside is having to order the cleaner, converter, etc. separate...at least when I was looking at it.

My 3.1415729 cents

Beezer · 05-03-2013, 12:19 PM

my 7 gal tank under construction....

finished

I welded & brazed every pinhole I could find but when I sloshed it with POR15 it still weeped out pinholes in a couple places. but it don't leak after the por. I don't remember when I did this but at least 6 years now. I did a kz1300 2 years before that & it was still good last I saw of it 3 years ago. all told I've por'd 4 tanks. I use it again.

dakman74 · 05-03-2013, 01:58 PM

Just out of curiosity, any idea how much ethanol in the fuel around where you live? I'm curious because here at 7000 ft they put in close to the 10% max (E10) and I've heard of a few guys with Jeeps having issues with the POR softening up and coming loose, clogging the fuel pumps and such. I still use the products for high-temp coatings (I have some stock AMC V8 manifolds I'm about to install on my CJ5 that I just finished PORing).

http://www.por15.com/US-STANDARD-TAN...oductinfo/TSG/

Just found this...so makes me wonder if they guys were using older versions of POR15. :-S

k-moe · 05-03-2013, 09:12 PM

Either older versions, or improper prep work.

R'oli · 05-06-2013, 09:04 PM

Por 15 seems to be the product of choice. going to try electrolysis method to remove majority of rust first. boys at work say "use coca cola; it will work faster"...thoughts?

04-28-2013, 09:39 AM	#1
R'oli ^OP Gnarly Adventurer Joined: Dec 2006 Location: Durham Region, Ontario, Canada Oddometer: 202	Project Bike Kawasaki EX500 + KLR I have an EX500 coming my way, I have heard a KLR 650 front end and rear end will strap right on, does anyone have any experience with this, or know where I could find out if this is true?

05-02-2013, 06:12 PM	#9
ban Adventurer Joined: Mar 2007 Location: Land of Lincoln Oddometer: 26	Similar project http://advrider.com/forums/showthread.php?t=741790 __________________ Never argue with a fool; onlookers may not be able to tell the difference. - Mark Twain Experience is what you get when you don't get what you want. - Dan Stanford

05-03-2013, 01:58 PM	#13
dakman74 moto-butcher expert Joined: Apr 2013 Location: Los Alamos, NM Oddometer: 22	Just out of curiosity, any idea how much ethanol in the fuel around where you live? I'm curious because here at 7000 ft they put in close to the 10% max (E10) and I've heard of a few guys with Jeeps having issues with the POR softening up and coming loose, clogging the fuel pumps and such. I still use the products for high-temp coatings (I have some stock AMC V8 manifolds I'm about to install on my CJ5 that I just finished PORing). http://www.por15.com/US-STANDARD-TAN...oductinfo/TSG/ Just found this...so makes me wonder if they guys were using older versions of POR15. :-S __________________ F-it...let's ride!

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04-28-2013, 11:39 AM	#2
Beezer Beastly Adventurer Joined: Oct 2004 Location: Anchorage, formerly Spenard (hub of the universe) Oddometer: 4,425	don't know if that is true. look up the KLE500 (available in Europe). it's the ds version using that engine as a base. it had different cams, etc to move the power band down. it was on my list to build one.... might still. it would be cool if there were bolt ons. can't imagine that it would be too hard to adapt something.... if it came to that the klr front end would not be 1st choice

04-28-2013, 08:23 PM	#3
R'oli ^OP Gnarly Adventurer Joined: Dec 2006 Location: Durham Region, Ontario, Canada Oddometer: 202	Breezer, Only reason the KLR front end is I may have one available. It will be a Frankenbike, I don't want to spend a tonne of money or I'd go buy something else. Any suggestions would be appreciated.

04-28-2013, 10:52 PM	#4
Beezer Beastly Adventurer Joined: Oct 2004 Location: Anchorage, formerly Spenard (hub of the universe) Oddometer: 4,425	Ricor valves in the klr forks work wonders.... I have 'em in mine. if I was going from scratch I might choose something better, but if you already have them they can be made decent. I have many years on klr's, contact me if you go that way, there are a couple tricks even if you stay stock

04-29-2013, 01:48 PM	#5
R'oli ^OP Gnarly Adventurer Joined: Dec 2006 Location: Durham Region, Ontario, Canada Oddometer: 202	Breezer, that would be great, picking up the EX this week and awaiting reply from KLR owner, engine blown and wants to part it out. But if there are other options I am interested in hearing all you have to contribute. I don't want to buy the KLR parts if they are not a fit, require extensive mods, or there are better options.

05-02-2013, 05:21 PM	#7
R'oli ^OP Gnarly Adventurer Joined: Dec 2006 Location: Durham Region, Ontario, Canada Oddometer: 202	Internal of tank is in bad condition, any suggestions on liner products?

05-03-2013, 06:39 AM	#10
yokesman Gnarly Adventurer Joined: Sep 2008 Oddometer: 196	there is also the kle 500 that the rest of the world gets ,a quick check on the net brought up only an italian forums site but many reviews and comments like"how come my kle500 handles better than my gs.?" a high end builder uses that engine for their RTW bike.

05-03-2013, 12:19 PM	#12
Beezer Beastly Adventurer Joined: Oct 2004 Location: Anchorage, formerly Spenard (hub of the universe) Oddometer: 4,425	my 7 gal tank under construction.... finished I welded & brazed every pinhole I could find but when I sloshed it with POR15 it still weeped out pinholes in a couple places. but it don't leak after the por. I don't remember when I did this but at least 6 years now. I did a kz1300 2 years before that & it was still good last I saw of it 3 years ago. all told I've por'd 4 tanks. I use it again.

05-03-2013, 09:12 PM	#14
k-moe Gnarly Adventurer Joined: Jun 2012 Oddometer: 191	Either older versions, or improper prep work.

05-06-2013, 09:04 PM	#15
R'oli ^OP Gnarly Adventurer Joined: Dec 2006 Location: Durham Region, Ontario, Canada Oddometer: 202	Por 15 seems to be the product of choice. going to try electrolysis method to remove majority of rust first. boys at work say "use coca cola; it will work faster"...thoughts?