Frankenstein ADV bike

Discussion in 'The Sandbox - AKA Flatistan' started by yermaun, May 25, 2013.

  1. yermaun

    yermaun Been here awhile

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    Looking to replace my beloved KLR (sold due to contracting orange fever) however much the KLR was a pig in the sand & unhappy @ highway speeds I still miss it, but I would like to improve on it, so I'm considering a Frankenstein build. I have a DR650 with a shot motor & an EX500 left over from my road racing days, it appears that with some fabrication the two could merge, any inmates undertaken such a project?
    #1
  2. DualSportDad

    DualSportDad Long timer

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    I never have but I have been thinking about a ninja 650 engine in a KLR.

    Sent from my Nexus 7 using Tapatalk 2
    #2
  3. yermaun

    yermaun Been here awhile

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    The Ninja 650 is a great little power plant, light, powerful, compact & reliable, it was actually my first consideration for this project. But there are a couple of drawbacks, the EX650 is fuel injected with down draught intake & high volume air box, neither the KLR or DR can accommodate that layout without major modification, also the EX650 uses a submerged fuel pump ( in the tank) & the 650 hangs in its frame as a stressed member so the mounts are not in an ideal position. I am going forward with the EX500 my plan is to utilize the lower cradle of the EX500 chassis & merge it with the DR main frame. I will post pics soon meanwhile I need to sell my old DT1 to help finance this project.
    #3
  4. motomike14

    motomike14 Thumper Crusader

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    sanjoh built a dirt ninja from a wrecked 650 ninja. He didn't swap chassis but made a pretty nice rig. There's a lot of such projects under "some assembly required."
    #4
  5. DualSportDad

    DualSportDad Long timer

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    I look forward to seeing how this turns out.

    Sent from my Nexus 7 using Tapatalk 2
    #5
  6. jaydee1445

    jaydee1445 Footpeg Crash Tester

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    All are valid reasons to go with the 500 :deal
    #6
  7. Huzband

    Huzband Team Dirt

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    What about yanking the EFI & put a carb or two in it's place? Could it be rewired around that?
    #7
  8. yermaun

    yermaun Been here awhile

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    Switching from fuel injection to carbs can be done relatively easily but there is still the packaging issue, the EX650 intake is a downdraft which requires alot of room directly above it that would be quite difficult to accommodate on a back bone type chassis used by the KLR & DR. Of course the intake could be altered but I don't have the time or resources to run that to ground, quite simply the EX650 would be a more desirable power plant to use but the EX500 is easier to work with, not to mention less expensive & I already have one. I will be stripping down the DR today anyone looking for a 93 DR650 lump with bad cam let me know.
    #8
  9. yermaun

    yermaun Been here awhile

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    [​IMG]
    #9
  10. yermaun

    yermaun Been here awhile

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    :eek1[​IMG]
    #10
  11. motomike14

    motomike14 Thumper Crusader

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    :lurk
    #11
  12. yermaun

    yermaun Been here awhile

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    EX lump installed[​IMG]
    #12
  13. yermaun

    yermaun Been here awhile

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    crappy pics from phone[​IMG]
    #13
  14. yermaun

    yermaun Been here awhile

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    [​IMG]
    #14
  15. yermaun

    yermaun Been here awhile

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    [​IMG]
    #15
  16. PFSGATORS

    PFSGATORS Adventurer

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  17. yermaun

    yermaun Been here awhile

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    Yup I've seen several KLR/650R's since I started this build, some of them very nicely done too.
    #17
  18. yermaun

    yermaun Been here awhile

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    :clap[​IMG]
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  19. sanjoh

    sanjoh Purveyor of Light

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    Congrats:deal
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  20. Vico1

    Vico1 The Maestro

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    Looks great but I would expect that from anyone with a shop floor like yours!:eek1
    #20