Hondo's 2008 KLX450R Build

Discussion in 'Some Assembly Required' started by Hondo, Dec 8, 2012.

  1. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    Thanks-

    Soon I'll be posting up the details of the rest of the bike.

    Posted from my Galaxy S3
    #21
  2. Wentjo

    Wentjo Been here awhile

    Joined:
    Aug 9, 2012
    Oddometer:
    421
    Location:
    Lakewood, CO
    Looking good:clap
    #22
  3. sidetrack one

    sidetrack one Chief Tiddler

    Joined:
    Jul 2, 2006
    Oddometer:
    6,149
    Location:
    hole shaven area
    That is some very nice bike prep you got going on there Hondo, well done!:clap
    #23
  4. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    Now some more updates....

    The forks on the KLX450R are the same ones as the KX450F, and need to have their pressure bled regularly.

    The forks have a recessed fork bleeder screw in the fork cap that when unscrewed, will allow the pressure within the forks to equalize with the ambient pressure. A better option is a set of push-to-bleed speed bleeders.

    The KLX & KX both need tall bleeders to clear the cap hex nut, so I chose to use some STR Offset Adapters and a set of their Speed Bleeders -

    [​IMG]

    The bleeder screw is at the top of the cap-

    [​IMG]

    Installation is simple- remove the stock bleeder screws, lube the small O rings on the adapters and screw the adapters into the fork. Then screw the bleeders into the adapter.

    Here are a few pics of them installed-

    [​IMG]

    [​IMG]
    #24
  5. TOMMY B

    TOMMY B PRODRIVE

    Joined:
    Feb 28, 2005
    Oddometer:
    153
    Location:
    Taxes paid Too: Brewster, New York KLX 450R D/S
    Nice, KLX 450 R :jive

    I like all your upgrades & your Gas Tank looks great too I need to put one on my bike soon.

    TOMMY B

    RALLY ON /////////////
    #25
  6. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    Just to help anyone who does not already know, anytime you bleed off the forks, the bike needs to have the forks fully extended.
    You can do it on a stand or even on the side kickstand but you need to lift the bars a bit and make sure the forks are topped out while you losen and retighten the bleeders...or if you have the push bleeders it is easier, but they still need to be and stay extended while you depress the bleeder.
    :1drink
    #26
  7. wbunt

    wbunt Been here awhile

    Joined:
    Jul 28, 2009
    Oddometer:
    427
    Location:
    Divide
    Nice build , great timimg , I just bought a KLX450 and have ordered some of the parts to get mine titled . Thanks !
    #27
  8. CHECK_OIL

    CHECK_OIL Been here awhile

    Joined:
    Mar 19, 2011
    Oddometer:
    374
    Location:
    Midland Va.
    Thanks, good tip!:thumb
    #28
  9. wbunt

    wbunt Been here awhile

    Joined:
    Jul 28, 2009
    Oddometer:
    427
    Location:
    Divide
    Just put the Pro Billet Peformance insert in mine . Very nice , sounds good without being too loud and runs better .
    #29
  10. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    cool!

    Sent from my ASUS Transformer Pad TF300T using Tapatalk HD
    #30
  11. DirtReeper

    DirtReeper Been here awhile

    Joined:
    May 8, 2011
    Oddometer:
    507
    Location:
    Southern Utah
    You gonna let us ride at Moab Hondo? :evil
    #31
  12. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    I'mk just hoping that I will be able to make Moab this year!
    #32
  13. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    When I was testing the electrical system for a 12vdc LED headlight replacement, I found that the stock KLX450R stator was not capable of maintaining a minimum 12v at the battery with the LED headlight on.

    So I sent the stock stator to Baja Designs and had them rewind the stator HERE.

    [​IMG]

    I also ordered their regulator/rectifier HERE-

    [​IMG]

    Side cover removed along with the stator-

    [​IMG]

    The BD Regulator / rectifier fit in the stock location- -

    [​IMG]

    I am happy to say that with the LED headlight on High and both cooling fans running, the stator has no problem keeping up with electrical demand.

    I'll be adding hard wiring for a Montana 600 GPS this week & don't anticipate any issues - :D
    #33
  14. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    To say that the stock 35 watt, AC powered headlight on the KLX450R is lacking is a huge understatement.

    Once the bike is plated the stock headlight is no more that a headlight in the legal sense and has no practical output at night.

    So I decided to upgrade the stock headlight mask with an LED light that I bought from the Vendors section, ADV Monster-

    http://advrider.com/forums/showthread.php?t=821159

    Light specs -

    • Wide Beam
    • 3600 lumens
    • Cree XM-L T6 LEDs
    • 2.4 amps (28 watts) @12v
    • aluminum housing
    • Length: 70mm , Diameter 55mm
    • Black durable coating
    • o-ring sealed housing
    • one meter wire lead
    • includes flat mount mounting option - (stainless)
    • shatter resistant lens


    I bought the light, variable output controller, and light holder (to be fitted to my own mask mount).

    After analyzing the electrical system on the KLX450R, I found a switched 12v circuit that I would use to control the headlight through a 12v relay. That way the headlight would only run when the engine was running.

    I would control the headlight by using a headlight switch that I bought from Paul at Highway Dirt Bikes - http://www.highwaydirtbikes.com/HDB...switches&sid=076k4qbn203x8c320rw736d3j8c05cf2

    [​IMG]

    I did have to move the electrical wiring inside the switch in order for it to properly control the Variable light controller from ADV Monster-

    [​IMG]

    The ADV Monster light controller has one output that is switched between full 12 volts and the variable output. The controller allows you to use the full 12v as high beam and the the reduced setting as low beam. The controller uses a seperate 12v line to know when to go to full 12v, and the High position of the switch provides that.

    Here is the stock headlight mask with the stock bulb-

    [​IMG]

    With the light bulb removed I found that the Model 60 LED light from ADV Monster would be a good fit in the mask-

    [​IMG]

    So I opened up the mask with a hot knife -

    [​IMG]

    Then I needed to create a flat plate that I could mount the light to. Cardboard first-

    [​IMG]

    Then I made a hole for the LED Model 60-

    [​IMG]

    I mounted the light bracket from ADV Monster to the plate & checked the assemble for fit-

    [​IMG]

    [​IMG]

    I then used some "Great Stuff" expanding foam to attach the mount to the mask- weighted it down with some big sockets. I did this in small stages so that I did not get any foam on the Model 60 light itself- I wanted to be able to remove it if necessary-

    [​IMG]

    After the foam was dry I trimmed off the excess and then drilled 4 ventilation holes through the foam & the mask - you can see the holes in the 4 corners of the reflector-

    [​IMG]

    Here it is mounted on the KLX450R-

    [​IMG]

    In test rides I have found the light to be a huge improvement over stock, and more than adequate for street or trail riding.
    #34
  15. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    I found that the stock shifter was too short for me when wearing my Sidi Crossfire boots, so I ordered a Hammerhead Designs extended shifter for the KX450 -

    http://www.hdmoto.com/ProductDetails.asp?ProductCode=KXF450SL

    I ordered the 15 mm longer shifter-

    [​IMG]

    Installed on the bike-

    [​IMG]

    [​IMG]

    On the trail I found that it was much easier to control my shifting- well worth the expense!
    #35
  16. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    I wanted to have the best designed, strongest handguard system available and luckily for me, Highway Dirt Bikes is right up the road from me in Denver.

    The great thing about their handguards is the top clamp. Unlike many systems whose inside attachment point is the handlebar itself, HDB uses it's unique top clamp that attaches to the handlebar mount, creating a super strong attachment point.

    After I discussed the top clamp configuration with Paul, I also decided to use his TailTech Striker Mount with the guards & top clamp.

    I decided to wire in a keyed ignition & electrical switch, LED turn light indicators, LED Low & High Beam indicators, and 2 switch positions- one for the fan cooling system & one reserved -

    [​IMG]

    When I bought my guards I chose to use the antivibration threaded handlebar inserts with the new Pro Taper CR High handlebar.

    HDB supplies the insert, tap & alignment collar-

    [​IMG]

    Here I'm tapping the bar end using the supplied tap & alignment collar-

    [​IMG]

    Tapped & insert installed-

    [​IMG]

    [​IMG]

    When installed, the guards are super strong- no pulling out of the bar!

    Here's a pic of one of the 12v Headlight beam indicator LEDs I used in the top clamp. I toned it down a bit with some black paint-

    [​IMG]

    Here's a shot of a set of 3/4 inch tall bar risers that I also got from HDB- this gives me an easier reach when standing and supplies better clearance between the Scotts Damper and the LED wiring-

    [​IMG]

    Completed shots-

    [​IMG]

    In this shot you can see the HDB Perch Switches on the right side of the bar that are used as Start & Stop switches and the Fold Out, Hideaway Mirrors-

    [​IMG]
    #36
  17. singleslammer

    singleslammer Adventurer

    Joined:
    Jan 14, 2013
    Oddometer:
    23
    Location:
    Central Missouri
    Cool stuff man. Thanks for pointing out that LED head lights. I wasn't aware that there was an option that inexpensive. I have already ordered one of their three bulb units.
    #37
  18. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    I found out that the stock KLX450R electrical system output for the stock headlight was AC, so the stator upgrade & LED headlight really should go together.

    I did try the LED headlight with a direct battery connection but stock
    stator output was still too low to adequately charge the battery.
    #38
  19. singleslammer

    singleslammer Adventurer

    Joined:
    Jan 14, 2013
    Oddometer:
    23
    Location:
    Central Missouri
    I am actually trying out a few options (everything from Harbor Freight lights to Clearwater LEDs) for a new product that my company is coming out with soon. If these are as good as people say on here, this will be an excellent option for our system. One of my partners rides an XR650R Honda that has the same issues with the Stator and AC power. It sucks that the lights that might run on such a low output system (like the XR and the KLX) are ruled out due to being DC only.
    #39
  20. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
    Aug 3, 2006
    Oddometer:
    10,063
    Location:
    Front Range, CO
    Suspension update-

    I just checked the sag of the rear suspension and found that the spring that is installed is woefully preloaded for my 210 lbs + riding gear & tools.

    So after talking with the the folks at Racetech, I ordered a spring for the shock & will be documenting the upgrade soon.
    #40