KLR 650 Modifications

Discussion in 'Thumpers' started by VascoMerlin, Aug 24, 2006.

  1. RustySpokes

    RustySpokes Two-bit throttle bum

    Joined:
    May 13, 2004
    Oddometer:
    1,114
    Location:
    Pueblo, CO
    Do you know if you can still get the engine out if needed?
  2. TengaiJohn

    TengaiJohn Long timer

    Joined:
    Apr 24, 2006
    Oddometer:
    3,127
    Location:
    Tappan, NY
    My pegs are welded and I can get the engine in and out of the frame.

    [​IMG]

    [​IMG]
  3. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    3,899
    Location:
    Garden City, Michigan
    <!-- / controls above postbits --><!-- end content table --><!-- / end content table --><!-- post #19821831 --><TABLE id=post19821831 class=dg-post border=0 cellSpacing=0 cellPadding=0 width="100%" align=center><TBODY><TR><TD class=thead colSpan=2>[​IMG] Today, 12:13 PM
    <!-- #dg-post-header-date -->#1
    <!-- #dg-post-header-count -->

    <!-- #dg-post-header --></TD></TR><TR vAlign=top><TD class="dg-post-user dg-align-center smallfont" width=175>[​IMG] GAS GUY<SCRIPT type=text/javascript> vbmenu_register("postmenu_19821831", true); </SCRIPT>
    <!-- #dg-post-user-name -->Beastly Adventurer
    <!-- #dg-post-user-title -->[​IMG]
    <!-- #dg-post-user-avatar -->Joined: Jul 2007
    Location: Garden city, Michigan
    Oddometer: 1,637


    <!-- #dg-post-user-info --></TD><!-- #dg-post-user --><TD id=td_post_19821831 class=dg-post-content>KLR Seat Concepts install
    <!-- #dg-post-title --><!-- message -->I ordered a Seat concepts seat kit for my 2008 KLR in the firmer than standard foam.So I figured I would share some pics and info in case anyone is interested.

    The new foam is much much nicer.It is not only wider but much denser and of high quality.

    [​IMG]

    After removing the 70 or so staples and removing the old cover and foam you want to smooth any sharp edges on the pan.
    I also smoothed all the little dimples from the old staples.
    Now is also a good time to check your pan for any clearace issues against your tank,especially if you have a aftermarket tank.
    I have a IMS 10 gallon tank and the left side is tight so I shaved a little off of the pan on that side which helps on installing the seat because the 2008 also has the little bolt on the tongue of the seat.

    [​IMG]

    Then I used a little 3m adhesive spray in a few areas to hold the foam on the pan before stapling on the cover.
    Here are a few shots of the foam on the pan before I put on the cover.

    [​IMG]
    [​IMG]
    [​IMG]

    I followed the instructions and stapled the cover on.It is kind of hard to get all the wrinkles out of the front area.Even after I get them out ,a few seem to come back after sitting on the seat.But overall I am happy with it for my first time .

    [​IMG]

    I chose the EMBOSSED cover with the small dimpling in it.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Then I put the alaskan leather sheepskin over it.

    [​IMG]

    [​IMG]

    In the instructions they tell you they use a staple gun from Harbor freight tools.So I went and bought one on sale for $21.99
    and let me tell you It works nicely.
    It is the small body 20 gauge wide crown gun and it shoots the arrow T50 staples just like the traditional silver hand stapler.

    [​IMG]

    You go to Home Depot to buy the staples.I used 1/4 inch staples for most of it and 5/16 in a few areas where the material overlapped.

    [​IMG]

    I have only went for a short ride so far but am impressed with the seat.
    It is the same shape and angle as stock but wider and firmer and that is what they advertise.It is a huge improvement over stock,but I think they should also offer a FLAT seat option also.
    I prefer a flat seat and in the future I may take the cover off and take a taper cut off of the seat to flatten it more but for now I am going to ride it as is .
    I hope this helps anyone interested in this seat.
    <!-- / message --><!-- sig -->__________________

    </TD></TR></TBODY></TABLE>
  4. RustySpokes

    RustySpokes Two-bit throttle bum

    Joined:
    May 13, 2004
    Oddometer:
    1,114
    Location:
    Pueblo, CO
    Thanks! My seat concepts kit is supposed to arrive tomorrow...
  5. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,403
    Location:
    Tulsa... it's OK
    I don't know first-hand, but I'd think yes. There is clearance at the top side of the motor. Only the aft motor mount is a flush one with a through-bolt. The top and front mounts are offset. I think it can be done.


    ...


    Where has Willys been lately?
  6. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    3,899
    Location:
    Garden City, Michigan
    He is prolly tired of youse guys always chewin on his ass.
  7. Myfuture_yourdebt

    Myfuture_yourdebt Banned

    Joined:
    Jun 21, 2011
    Oddometer:
    372
    Location:
    Front Range, CO
    I'm experimenting with a pre cold start sump heater and lower radiator hose heater on my KLR650 over this winter and will report back with results and my impressions.
  8. SkiBumBrian

    SkiBumBrian DualSport Crazy !!

    Joined:
    Jan 15, 2012
    Oddometer:
    1,051
    Location:
    Redding, CA
    Those few wrinkles will come out in time as the cover settles and shrinks, mine did. You did a great job!
  9. Aron31

    Aron31 Been here awhile

    Joined:
    Dec 15, 2010
    Oddometer:
    113
    Location:
    Western Chicago Il
    Who out there has thoroughly tested their crash bars? Just wondering what everyone's experiences have been. Seems like the 2 big ones are the sw motechs and the happy trails pd kit. I think givi also released some as well. They all look great brand new but what about after a couple offs? Any bending? Tweaking? Fitment issues? I just don't want to waste the money on something that's going to go to crap the first nap it takes.
  10. lexluther11

    lexluther11 Ride,Eat,Rest-Repeat

    Joined:
    Feb 21, 2010
    Oddometer:
    1,240
    Location:
    Vancouver, BC, Canada
    As much as I try I can't seem to damage my KLR......the SW Motech crash bars work very good.

    [​IMG]
  11. RandoCommando

    RandoCommando Wannabe

    Joined:
    Oct 12, 2011
    Oddometer:
    1,542
    Location:
    Philthadelphia, Pennsylvania
    I can verify that my HT PD Nerf Bars work.
    I went down in WV and the highway bar bent but my bike was spared major damage.
    My leg is another story.
    I fractured my distal fibula.
  12. doogiepooch

    doogiepooch Been here awhile

    Joined:
    Jul 27, 2010
    Oddometer:
    980
    Location:
    Canton, NC

    Had SW's on my 2 KLR's. My 88 my rear tried to pass my front on some loose gravel in a sharp turn I over corrected and face planted (hard) into the pavement at about 30 mph. Slight scrape on the bars and a broken mirror are all that happened. No deflection or bending. Some touch up paint and it was good as new. My 2012 has fallen over twice, one on each side on pavement, no attempt to catch it. I have a hair scratch on one side of the bars, the other side I can't even find a scratch. I can't comment on the Happy Trails bars, I've seen some youtube videos after drops and wrecks and guys seem to be happy with how they've held up. I have read of some slight fitment isses on the HT bars but nothing some pulling and tugging wouldn't fix. I think between the 2 it's really a style preference. My personal thoughts are the SW's are way sexier. The Givi's just don't protect enough for my taste, I've heard other mirror that. Just do one thing, don't fall for the $100 hwy pegs from SW. I bought them for my 88' and they sucked. On my 2012 I ordered some $7 folding foot pegs and they worked perfect. SW's all the way.

    [​IMG]
    [​IMG]
    [​IMG]
  13. lexluther11

    lexluther11 Ride,Eat,Rest-Repeat

    Joined:
    Feb 21, 2010
    Oddometer:
    1,240
    Location:
    Vancouver, BC, Canada
    Just had Hot Cams installed and I'm liking the increase in power. I haven't had a chance to really try them out because of all the rain we are getting but I do notice the torque and lower rpm at cruise. Will let you know more once I give them a good workout.

    [​IMG]
  14. Jettn Jim

    Jettn Jim This is Liv'n!!!

    Joined:
    Mar 28, 2010
    Oddometer:
    1,839
    Location:
    NE PA Some... PNW Some... On HIGH ADVENTURE Most!
    Hey Gas Guy... nice job, I think your gonna find that your new SC is more comfy WITHOUT your Alaska Leather sheepskin...:huh Yea I know doesn't add up but on a little 4,500mi hop down to FLA this past February that's what I found out.
    Then told Oldstove over at KLRWorld and after testing it out on his he said hmmmm no kidd'n yer right.
    Check it out and get back to me... it's weird! :eek1

    As for the SC I'll prob sell mine when I get back from the ride I'm currently on, since it just sits gathering dust in the shop anyhow....:deal
    Foam weighs a ton and I like my RM betta.

    As for welding the pegs.... not for me since I swap engines more than most guy's swap tires. :evil
    I need it to be as smooooth as possible when I've gotta 120lbs hang'n on on my finger tips.
    But I understand some doin' it.

    Peace,
    JJ
  15. SkiBumBrian

    SkiBumBrian DualSport Crazy !!

    Joined:
    Jan 15, 2012
    Oddometer:
    1,051
    Location:
    Redding, CA
    Keep them adjusted to mid tolerance and check them often. They are not as forgiving as stockers, they have a tendency to wear if not to spec. Did you do headwork or 1mm over valves?
  16. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    3,899
    Location:
    Garden City, Michigan
    Okay, thanks I will try it without the sheepskin.
  17. Jettn Jim

    Jettn Jim This is Liv'n!!!

    Joined:
    Mar 28, 2010
    Oddometer:
    1,839
    Location:
    NE PA Some... PNW Some... On HIGH ADVENTURE Most!
    Had a set of them in engine #1 for about 8,500mi now.... along with a few other mods:wink: Goood stuff!
  18. Jettn Jim

    Jettn Jim This is Liv'n!!!

    Joined:
    Mar 28, 2010
    Oddometer:
    1,839
    Location:
    NE PA Some... PNW Some... On HIGH ADVENTURE Most!
    Had a set of them in engine #1 for about 8,500mi now.... along with a few other mods:wink: Goood stuff!

    Yea surprised the Hell outta me when I put the skin away during a couple rainy days. Good thing is you won't have to make room to store your skin during storms anymore, just leave it at home. Only seat I ever used that didn't like the Lamb?!? :hmmmmm
  19. judjonzz

    judjonzz Beastly

    Joined:
    Mar 14, 2002
    Oddometer:
    2,031
    Location:
    Not Fargo, not Butte, not Cheyenne
    Since 2003, I have an IMS tank instead of crash bars. The bike has been down hard many times without damage to the radiator. Jeffie Ecker did manage to bend my fan shroud once. The tank kinda looks like crap, but no worse today than it did in 2005. For my money, it's the way to go: rad protection and an extra 75-100 miles range for less than the price of crash bars.
  20. lexluther11

    lexluther11 Ride,Eat,Rest-Repeat

    Joined:
    Feb 21, 2010
    Oddometer:
    1,240
    Location:
    Vancouver, BC, Canada
    I have a Arias 688 piston and oversize SS valves and it's all been done to spec, run then re-checked for clearance.:D