another versys powered klr

Discussion in 'Some Assembly Required' started by thomas.tc.young, Jul 20, 2012.

  1. thomas.tc.young

    thomas.tc.young Been here awhile

    Joined:
    Sep 23, 2010
    Oddometer:
    863
    Location:
    NYC
    well here it goes guys another versys powered klr project. mostly because i saw a complete versys partout and couldn't pass up the deal and the proximity.

    Here's the frame.
    [​IMG]

    and the engine.
    [​IMG]

    everyone knows it doesn't fit in. i plan on copying some of klrsys project because its the most well documented and makes sense to me as well.

    first thing's first, flip those carb boots
    [​IMG]

    their directional which is why you have to flip the carbs as well
    [​IMG]

    that's it for now. time to get out the sawzall
    #1
  2. kajj

    kajj Been here awhile

    Joined:
    Aug 28, 2011
    Oddometer:
    192
    Location:
    In northern Sweden
    subscribed:lurk
    #2
  3. 2fast4u

    2fast4u Been here awhile

    Joined:
    Jan 6, 2011
    Oddometer:
    749
    Location:
    Tennessee
    Cool project!! I know this has been done before but never looked at a build. What fuel tank are you going to run? Just wondering about the fuel pump.
    #3
  4. thomas.tc.young

    thomas.tc.young Been here awhile

    Joined:
    Sep 23, 2010
    Oddometer:
    863
    Location:
    NYC
    Im basing most of my project on klrsys's build thread. He ran the stock tank and rigged it so the hose ran into an external fuel pump mounted under the seat. I'm looking at the fuel pump and figuring out my options but that looks like the simplest way currently.
    #4
  5. 2fast4u

    2fast4u Been here awhile

    Joined:
    Jan 6, 2011
    Oddometer:
    749
    Location:
    Tennessee
    I was goiing to put a ninja motor in crf 450 frame but the fuel pump worried me. Will the fuel pump be submerged in fuel because thats what keeps the pump cool and with a external fuel pump you have to think safety. I was thinking about a fuel tank off a 610 husky but don't know that would work. Would have to compare fuel pumps. Will be watching.
    #5
  6. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    The stock Versys fuel pump has to be put in a can for cooling. If anyone knows of a suitable small external pump and regulator I would like to hear about it and I'm sure Tom would also. The specs for the stock pump:

    With engine idleing: 294 kPa (3.0 kgf/cm2, 43psi) with fuel pump running
    Discharge: 60ml or more for 3 seconds (72 liters/hr)
    #6
  7. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,445
    Location:
    On a RTW ride - next stop USA!
    The Suzuki LT-R 450 quad pump is perfect. It's about 4-5" long and should put out enough juice for 65 RWHP.

    [​IMG]
    #7
  8. 2fast4u

    2fast4u Been here awhile

    Joined:
    Jan 6, 2011
    Oddometer:
    749
    Location:
    Tennessee
    The problem with an external pump is the fuel lines. If you was to wreck and break or crack a fuel line with that much fuel pressure it could be bad real bad.
    #8
  9. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,445
    Location:
    On a RTW ride - next stop USA!
    I don't really get the concern? :scratch

    The pump and lines would be tucked in under the tank, so they won't be damaged if you crash. If you use fuel injection rated hose it will not split either.

    And most importantly, the only difference between internal and external pump is the line going from the tank to the pump, and that is not even under pressure?
    #9
  10. 2fast4u

    2fast4u Been here awhile

    Joined:
    Jan 6, 2011
    Oddometer:
    749
    Location:
    Tennessee
    The stock line thats under pressure on the ninja is very short when you move it under the seat you will have two long fuel lines. This bike should be able to run over 120 mph. It just scares me not saying it wouldn't work. The tank off of a KTM or Husky that has the fuel pump in it would work and be safer and easier. Just :lol3my opinion.
    #10
  11. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    5,386
    Location:
    Sunshine coast qld
    You sleep with the lights on don't you.
    #11
  12. wibby

    wibby BrotherFromAnotherMother

    Joined:
    Mar 20, 2005
    Oddometer:
    10,663
    Location:
    Grass Pants Orygun

    :dic
    #12
  13. RedRaptor22

    RedRaptor22 Been here awhile

    Joined:
    Jan 24, 2012
    Oddometer:
    163
    Location:
    Louisiana
    I've worked on a few bikes that had external pumps, never heard of them turning into fire balls.

    Like that other guy said, the only difference would be a couple of inches of plain rubber fuel line from the tank to the pump, even mounted under the seat the bike would have to turn itself inside out for damage to occur.
    #13
  14. Kawidad

    Kawidad Long timer

    Joined:
    Jul 9, 2005
    Oddometer:
    5,112
    Location:
    Central Coast, Cal
    Facet makes some really nice, small external fuel pumps. They are a common upgrade on KTM Adventures. DAMHIK.

    As an example:

    http://www.aircraftspruce.com/menus/ep/fuelpumps_0facetelectric.html

    FAA rated, so.................... :deal

    BTW, since you have a bare KLR frame, I would suggest welding a small plate over the spine above the shock mount/down tube area. There is a lot of stress on that point is it is known to fail and be a weak point.

    I'm in. :lurk
    #14
  15. thomas.tc.young

    thomas.tc.young Been here awhile

    Joined:
    Sep 23, 2010
    Oddometer:
    863
    Location:
    NYC
    service manual reveals fuel pressure is 294kPa, 41.81psi and discharge is 83mL (2.8US oz) and more/10 sec. i dont think it will work with that lower flow rate, anyone else know if it would or wouldn't?
    #15
  16. 2fast4u

    2fast4u Been here awhile

    Joined:
    Jan 6, 2011
    Oddometer:
    749
    Location:
    Tennessee
    What about the ninja fuel pump?
    #16
  17. RedRaptor22

    RedRaptor22 Been here awhile

    Joined:
    Jan 24, 2012
    Oddometer:
    163
    Location:
    Louisiana

    It would with a regulator, your local autoparts store should have a couple of aftermarket performance brand fuel pumps sitting on the shelf as well.

    When I replaced the 3psi stock fuel pump on my royal star venture I found a mr. gasket pump at autozone for a whole $15, the stock was remote as well and retails for $145.
    #17
  18. divimon2000

    divimon2000 Been here awhile

    Joined:
    Apr 16, 2011
    Oddometer:
    628
    Location:
    Lake Champlain, Vermont
    Great project. Good luck.
    #18
  19. thomas.tc.young

    thomas.tc.young Been here awhile

    Joined:
    Sep 23, 2010
    Oddometer:
    863
    Location:
    NYC
    oops :evil

    [​IMG]

    and all done with a handsaw because i'm cheap like that!
    #19
  20. RedRaptor22

    RedRaptor22 Been here awhile

    Joined:
    Jan 24, 2012
    Oddometer:
    163
    Location:
    Louisiana
    Been there and done that on my old yamaha AT1, your going to look like a fiddler crab by the time this build is done lol.
    #20