KLR 650 Modifications

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

  1. GsVs

    GsVs Goin' Somewhere

    Joined:
    Dec 30, 2002
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    1,455
    Location:
    Hoosier (IN) USA
    I use Broccoli bands to keep the smell down !
  2. Grinnin

    Grinnin Forever N00b

    Joined:
    Dec 10, 2005
    Oddometer:
    2,981
    Location:
    Maine
    Only tangentially a KLR modification -- pockets inside the top box.

    [​IMG]

    These pockets hang from 4 of the 10 flathead machine screws that secure the piano hinge. I'll leave the tops open for now, but I think this will require that I go test it. :ricky Once the roads clear a little. :p3rry

    Last year I shortened a stuff-sack and the back of this set of pockets is the old top. I had to trim about an inch-and-a-half of fabric off that piece to make this. Does that qualify me for my "cheap as a KLR owner" merit badge? (I did not, however, save the inch-and-a-half that I trimmed off of this.)
  3. Yokomo

    Yokomo Gorilla Adventurer

    Joined:
    Sep 10, 2008
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    2,358
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    The Little Apple
    Installed a LEXX exhaust yesterday. Looks and sound great.
  4. ThomasVolomitz

    ThomasVolomitz New Old Stock

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    Aug 14, 2010
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    4,426
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    NE Ohio
    May I ask how much you have into the Lexx $?

    Thanks
  5. Aprilia

    Aprilia Been here awhile

    Joined:
    Sep 15, 2008
    Oddometer:
    790
    Location:
    Flagstaff, AZ
    Lexx is a good pipe for the money. They are still having broken spring issues but like always RMATV takes care of their customers. If its mostly street miles I'd suggest going with a pipe that doesn't need repacking. LeoVince is pretty good option/value for that.
  6. Yokomo

    Yokomo Gorilla Adventurer

    Joined:
    Sep 10, 2008
    Oddometer:
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    Location:
    The Little Apple
    I think its $179 shipped.
    [​IMG]

    The bottem spring goes on no problem, but there was no way the top spring was going to make it. So I cut a clothes hanger I have hanging around for odd uses and stuff like this. I just bent it around the pliers a couple times. Worked good for an extension.
    [​IMG]

    Really the only reason I wanted the exhaust was due to the crazy amount of heat the stocker put out.
  7. greasyboy

    greasyboy cur·mudg·eon

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    north central, PA
  8. ausfahrt

    ausfahrt mach schnell

    Joined:
    Apr 17, 2008
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    Location:
    Fl & Vt
    Cool! I didn't realize that they had redesigned the 1st gen windshield. I have a Parabellum on my GS and it's great, is that the tallest one?
  9. misterjack

    misterjack Universal

    Joined:
    Jan 18, 2013
    Oddometer:
    51
    Location:
    Cincinnati, Ohio
    I just purchased the same parabellum second gen for my '89 KLR and love it. the 20 inch provides great wind protection and doesn't get in the way off road.

    I would recommend to anyone looking for an upgraded windshield for me resistance.
  10. ThomasVolomitz

    ThomasVolomitz New Old Stock

    Joined:
    Aug 14, 2010
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    4,426
    Location:
    NE Ohio
    This is from a few pages back. Today I did 540 mostly freeway miles on the bike. The windshield worked great, even at 60-70 miles an hour. The laminar lip addition from MRA continues to be very solid.

    And the Sargent seat is the greatest.
  11. Dan Diego

    Dan Diego Long timer

    Joined:
    Dec 24, 2010
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    Location:
    San Diego, CA
    Doing the Doo. (KLR650 Balancer Idle Lever & Spring upgrade)<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
    Just a quick report for those KLR riders who may be as mechanically disinclined as I am. (That’s right: Put me in round room with 5 metal washers; I’ll lose two and break the rest.)
    <o:p></o:p>
    <o:p></o:p>
    I have about 1,100 miles on my 2011 Kawasaki KLR 650 and wanted to upgrade the balancer idle lever & spring (AKA: the Eagle Mike doohickey upgrade) before there was a problem. As you might’ve read, these issues have plagued KLRs for years yet Kawasaki has yet to stand up and implement a fix. Leave that up to a local boy, San Diego’s Eagle Mike (Eagle Mfg.) who fabricates and sells KLR stuff that Kawasaki should be using in their stock bikes. But I digress…
    <o:p></o:p>
    <o:p></o:p>
    I acquired new Eagle Mike doohickey and Thermo-Bob kits from a local rider who sold his KLR before he could install them. You may buy the kits on-line or from Eagle Mike’s shop.
    <o:p></o:p>
    <o:p></o:p>
    Anyhow, even though there is plenty of information about the installation process, to include the special tools that are required, I decided to have someone else do the work. I contacted Eagle Mike directly who recommended his friend and fellow gearhead Mike Sorchy who runs a high performance bike outfit (Epic Power) in the San Diego area. This meant I didn’t have to purchase or borrow the special tools required for the process (even though the local SDAR guys offered to give them to me at no cost).
    <o:p></o:p>
    Mike had not previously done the doohickey upgrade (http://www.eaglemike.com/Basic-lever-kit-basic-doohickey-kit-blk.htm) on a KLR so, in consultation with Eagle Mike, he estimated he could complete the work in under three hours. And that included the Thermo-bob kit (http://shop.watt-man.com/Thermo-Bob-for-KLR650-2008-and-NEWER-TB8.htm) and an oil/filter change. How could I pass up that deal?
    <o:p></o:p>
    I dropped my bike off with Mike @ Epic Power on Monday and picked it up on Thursday. I was charged under 3 hours of labor for the entire job. If you only want the doohickey work done, it will be less.
    <o:p></o:p>
    NOTE: It appears that Mike Sorchy will be doing a lot more of these jobs as the greater San Diego area is chock full of numbskulls like me.
    <o:p></o:p>
    Anyhow, contact me if I can provide any info on the process, or contact either Mike directly. If you're in the SD area and want this work done, here’s the contact info for Mike Sorchy:
    <o:p></o:p>
    Mike Sorchy/Epic Power<o:p></o:p>
    1145 Greenfield Dr. Suite H <o:p></o:p>
    El Cajon, CA 92021<o:p></o:p>
    O: (619) 356-3742<o:p></o:p>
    Mike.EpicPower@gmail.com<o:p></o:p>

    Useful links:<o:p></o:p>
    Watt-man.com<o:p></o:p>
    http://www.eagle-m-e.com/<o:p></o:p>
    eaglemike.com<o:p></o:p>

    Videos and step-by-step instructions can easily be located all over the I-net.<o:p></o:p>

    Take care, KLRistas!<o:p></o:p>
    Dan<o:p></o:p>
  12. IngoldWV

    IngoldWV Dingo

    Joined:
    Jan 12, 2012
    Oddometer:
    153
    Location:
    Parkersburg/Cross Lanes, WV
    [​IMG]

    [​IMG]

    FCR 37 MX Carb w/ T-4 slip on. Good throttle response and torque.

    Main Fuel: 170
    Pilot Fuel: 42
    Start Jet: 72
    Leak Jet: 60
    Pilot air: 75
    Main air: 200
    OBELP Needle 5th clip.
    Has QuickShot2 installed as well.
  13. eddie bolted

    eddie bolted BOING!!!

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    What kind of seat? Is it comfy?
  14. IngoldWV

    IngoldWV Dingo

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    Parkersburg/Cross Lanes, WV
    Don't know what it is. It's okay. It came out of my friend's garage. Seems to just be a shaved down stock seat. Its old.
  15. gunny_usmc

    gunny_usmc Semper Fi

    Joined:
    Aug 20, 2006
    Oddometer:
    397
    Location:
    Corning, NY
    been awhile since I posted in this thread, glad to see ya'll gettin it done ! No mods other than a 685 for me this year, spending most my money on riding gear, like the new darien pants and the hennesey hammock I just sprung for. I did mod the fairing on my '02 last year, works really good on the slab for wind and rain protection, far enough forward I don't worry about smacking my face into off road..
  16. Kawidad

    Kawidad Long timer

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    Jul 9, 2005
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    5,110
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    Central Coast, Cal
    I like it. :clap

    Do you any further details about the install? Also, why did you go with the 37mm versus the 41 or 39mm, which are the more common sizes for a 650cc engine? :ear
  17. IngoldWV

    IngoldWV Dingo

    Joined:
    Jan 12, 2012
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    I had to make the intake manifold spacer. It was made on CNC mill; 6061 aluminum. It is 0.800" long; 0.850" might make for better fit. Had to carve out the starter some and the bowl on the carb. Also, shortened the stock air boot and used 1/16" Nitrile lapped three layers to build the end to fit onto the carb; used some nitrile adhesive. The orange stuff is duct tape holding it together while the adhesive cures.

    I went with 37 mm because I had it from a bike I parted out, and I am not a fan of CV carbs. I thought it would be good to show it could be done as an option. I was looking for better throttle response and some better bottom end. I got that out of it; at least it feels that way.
  18. VascoMerlin

    VascoMerlin He'll Stab Your Cat

    Joined:
    Aug 15, 2006
    Oddometer:
    413
    Location:
    Indian Mills, New Jersey
    I know there are 1,000's of tire threads here, but since I created this thread:

    I just installed the Heidenau K60 Scouts on my KLR, and I must say that I am thoroughly impressed with both the on-road and off-road (sandy Pine Barrens) capabilities.

    I can't wait to see how they hold up, but from what I hear from our customers, 12,000mi is possible. Big difference from the D606's I took off at 3,500mi.
  19. SkiBumBrian

    SkiBumBrian DualSport Crazy !!

    Joined:
    Jan 15, 2012
    Oddometer:
    1,051
    Location:
    Redding, CA
    I checked out a pic of the Heidenau K60s since I had never heard of them before. The tread pattern seems eerily close to the MEFO explorers, which I thought were fine on road but totally worthless off road under any conditions. I have 606s on now, I think they stink on road and aren't any better than T63s off road. As soon as these 606s are done I am going back to the Michelins. Cheap, good all around performance. Soft compound means they don't last long but I think that is one of the things that lets them bridge that on/off road gap....
  20. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
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    3,718
    Location:
    Garden City, Michigan
    I think the mefos and heidis are made at the same plant.They are both from Germany.
    I ran a set of mefos years ago and was not impressed.
    I think they are too hard to have good performance,thats why they last so long.I suspect the Heidis may be similar.