'88 KLR650 project thread

Discussion in 'Thumpers' started by south, Mar 12, 2011.

  1. south

    south Been here awhile

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    Alright, should be good--and if it's not, lemme know and I'll just forget it and bag the whole thread. :D
    #21
  2. brucifer

    brucifer Long timer

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    There we go, we have pics! :thumb
    #22
  3. south

    south Been here awhile

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    If so, then thanks for driving the price up. :D

    Despite the fabrication/fitment hassles, I'm quite happy with my $25 front brake upgrade (would've been $60 total without the Pinwall refund), even moreso upon hearing the $250 price tag on the kit, thanks. Out of curiosity, does the kit MC come with/allow for an adjustable lever?
    #23
  4. south

    south Been here awhile

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    Thanks! Glad to hear I didn't just waste a bunch more time. :D
    #24
  5. Kevinhooa

    Kevinhooa Pitch pine slalom

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    Wow, south amazing writeup South. I enjoyed this whole thread. Your fabrication skills really came in handy here, and I'm glad you did so much experimenting with things. Looks like it was a fun project.
    #25
  6. guns_equal_freedom

    guns_equal_freedom Long timer

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    Get an over sized rotor.

    Nice project. :clap
    #26
  7. south

    south Been here awhile

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    Thanks, gents.

    GEF--no oversize rotor needed; a 2 finger pull will pretty much stand the thing on its nose. I'm very happy with the present braking capability of the bike (and it doesn't hurt that I weigh in at 150lbs.)

    Just received and installed my new levers--swapped out the stock KLR clutch perch for a ZX6R unit to match the MC and allow for the use of aftermarket adjustable, extendable, and folding levers:

    [​IMG]

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    [​IMG]
    #27
  8. south

    south Been here awhile

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    Last mod to the bike was to install a 3/4" (one-way) check valve to the crankcase breather to eliminate oil loss as the motor mists oil out the breather during normal operation. This mod has been so successful--bike hasn't lost a drop since installation over 8 months ago--that a similar set-up will go on my 250 Ninja commuter, which has always "processed" oil much like the KLR did: out the breather, into the airbox, then to the motor, and out the exhaust.

    Instead of routing to the airbox (and interfering with my choke lever install), the plan is to run a hose to a protected/shielded area up under the seat; the valve generates a slight negative pressure in the crankcase when the motor is running, and although it seals tight at that time (i.e., when the engine is running), I want to avoid a possible scenario where the hose end is underwater and the bike stalls and the thing sucks water into the crankcase.

    Valve:

    [​IMG]

    [​IMG]

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    Installed:

    [​IMG]
    #28
  9. schaffer40

    schaffer40 I look lived in.....

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    Nice work. I envy the the lathe skills.
    #29
  10. Kawidad

    Kawidad Long timer

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    I'm surprised I missed this when you originally posted it. But, better late to the party than never. Nice work, I like it a lot. :clap
    #30
  11. south

    south Been here awhile

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    Thanks, guys :thumb.

    Schaffer40--I have to say, it's just a cheap hobby lathe, and I'm a hack, but the thing has been incredibly handy to have for all sorts of (little) projects.

    As for the KLR, having come from an exclusively road/sport -bike background, and given the drubbing the model takes from many folks, I continue to marvel at just how much fun, and how (street) capable, the bike actually is as configured. Without question, absolutely one of my favorites.
    #31
  12. CalicoJack

    CalicoJack Been here awhile

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    Great info and write up. It will help me alot with my KLR project (Skunk Ape) Mine is not in as bad a shape but cost me twice as much...
    #32
  13. tdrrally

    tdrrally Long timer

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    makes me want a klr:D
    #33
  14. Pasch

    Pasch 1%er Adventurer

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    So South, what happened after that last mod?

    Have you changed anything since? I'm pulling the engine out the frame tomorrow, all is gonna be painted black, something durable but no powder coating (not much of a budget at the present moments)
    #34
  15. sasho

    sasho Dual Personality

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    Not only I learn from you mechanic and fab skills, but your writing is tremendously and engaging. :beer
    #35
  16. Kentuckysurfer

    Kentuckysurfer retrojets

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    Why didn't you just bolt on a different set of forks? I did 2 different swaps on 2 diff KLR650s, one with a WR426 set and another with a DRZ400 fork set. Much, much better braking and forking action all around...Of course it takes a bit more work to machine a steering stem to fit and a dash plate to relocate the gauges, but it was well worth the effort in the end. Plus, you have much more tuning available on the forks once done....overall I have to admit :rofl:rofl I ended up with 2 weirdass bikes, a Yamasaki and a Kawazuki...LOL!
    #36
  17. eddie bolted

    eddie bolted BOING!!!

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    Maybe i missed it,what was your total cost?
    #37
  18. Kentuckysurfer

    Kentuckysurfer retrojets

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    Do you mean the total costs on the Yamasaki and Kawazuki bikes? On the Yamasaki I paid about $200 for YZ426F forks w triple clamps/axle off ebay and I had an extra front brake system for an old Yamaha dirt bike already, so the machine shop to make a new steering stem was only $100...I did use a YZ front wheel I had already and made spacers......that's about it.........On the Kawazuki I bought DRZ fork set for around $250, used a DRZ front hub and a brake caliper/master cylinder (cost $120) and again another steering stem, maybe $450 to $500 total sunk into the swap..I loved the funky old KLR so much I wanted some DECENT brakes..a few hundred bucks for my safety was an easy investment to make....and what a difference on the bike! Stopping was awesome and so was the ride over crappy roads and off the hiway...the lock to lock steering with the DRZ fork setup was almost the same as stock, although as someone else pointed out on this site somewhere, the YZ fork swap narrowed the lock to lock range just a tiny amount, but nothing too annoying. The world of DIFFERENCE in the ride quality and stopping power made up for everything. One bike was a 2001 model and the other was a 1988 model w 15,000 original mi. No more hair raising, bone chilling worries if the bike would stop in time during panic stops in traffic....THAT was why I did it in the first place.....
    #38