KLR 650 Modifications

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

  1. KamikazeKLR

    KamikazeKLR Shorty on the 650

    Joined:
    May 1, 2012
    Oddometer:
    685
    Location:
    Winnipeg, Manitoba
    Hmmmmm! How do I know if it'll work with my GPS? And how would we go about doing this
  2. SkiBumBrian

    SkiBumBrian DualSport Crazy !!

    Joined:
    Jan 15, 2012
    Oddometer:
    1,051
    Location:
    Redding, CA
    A ram mount is a ram mount as far as I know. Mine fits my 2 different GPS units and my sheet scroll. Just PM Jim.....
  3. Wansfel

    Wansfel 50+ yrs on 2 wheels

    Joined:
    Sep 10, 2009
    Oddometer:
    1,558
    Location:
    Bitterroot Valley
    I use the RAM system for my ETREX Legend HxC. Use and existing mounting boss for the KLR with matching RAM Ball/stud and a handlebar clamp with Ball for the BMW LT. Easy to swap back and forth.

    Yes, the Legend screen is small, but very rugged and usable. The mounting system is very sturdy.

    Ram Bal mount on the KLR spare rear view mirror mount:
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    Etrex Ram mount (on BMW LT)
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    RAM handlebar clamp ( BMW LT/Etrex mount)

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    Etrex/RAM on KLR Handlebar
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  4. 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!
    Yes it's just a 1" ram ball on a handlebar clamp. Just PM me a mailing addy or the local post office. Note: I can send it general delivery in your name to your towns USPost office so you don't have to share your exact address. You can then pick it up there... No charge, I may even have an extra 3" arm for it. You would then just need the plastic ram holder/with ball that fits your specific GPS, that would in turn mount on the Ram arm.
  5. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    Time for little update:

    I added the HDB hand guards and a new bar. I crashed the sporty and had this set up on it and didn't even suffer a bent bar, that was at 75-80 mph. Very strong set up indeed.

    [​IMG]

    I decided to do a little fairing trim so I can run full lock if needed. I mean its not like this thing can get any worse looking. She has suffered a lot at my hands so whats a little tuck and trim

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    a little fab work and i can fill in these holes

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    I love how these mount to the handle bar clamps it adds a lot of strength

    [​IMG]

    [​IMG]

    a very solid product that is well thought out.
  6. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,405
    Location:
    Tulsa... it's OK
    I still need to ride with you someday, J-dubbs.

    Are you coming to SLAP?
  7. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    I'll be in the Texas Hill country that weekend. We do need to do a ride some time. I'll be in maine in june and chama, NM and around Colorado in july august time frame
  8. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,405
    Location:
    Tulsa... it's OK
    Oh... one "mod" that I just remembered and thought I would share.:deal

    If you're like me and ride your KLR nearly exclusively offroad and find your bike horizontal on occasion:D, then this might be a mod for you.

    Seems odd, but here goes. I trimmed the blades on my cooling fan by about 1/4". Why? Well, numerous times, I have dropped the bike on the left side and bent the cooling fan cage. I think I'm on my third fan now. I have an IMS tank and it flexes when traumatized.:evil

    First time it happened was during my first enduro. Fan cage bent a bit and the fan locked up because the fan could no longer turn. Melted the fan hub and the bike overheated. Had to quit the race.

    The trimmed fan blades still move a lot of air. There is likely a better solution, such as crash bars or a stronger fan cage(?). I saw a problem and made an adjustment. Haven't had an issue since. Take that as you will.
  9. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,405
    Location:
    Tulsa... it's OK
    Cool. My Tulsa crew and I might try to do a ride over to AR sometime and I'll let you know.

    I'll be doing the Train Robbers Enduro the weekend of June 9th.

    (No more KLR enduros though. :p3rry The beast is retired with her 4th place season trophy. I'll be on a KDX220R from now on...)
  10. dmottv

    dmottv Take the Long Way Home

    Joined:
    Jan 26, 2008
    Oddometer:
    429
    Location:
    NH Seacoast
    Mel, the RAM ball handlebar mount has a ball on a U clamp that clamps to the handlebars. In the picture below, my Nuvi is inside a RAM Aquabox with another RAM ball bolted on the back of the box, with a RAM arm connected to the RAM handlebar mount. It's hidden abit by the wires. The RAM Arm bridges between the two and has spoon type holders on each end with a spring clamp to adjust and grab each ball. It's difficult to explain, but straight ahead when you see it. It works well enough that I have a handlebar mount on my dirtbike and on my atv, and move the Aquabox with the Nuvi between them all. The other way to go is to get a specific holder for your Nuvi that has a RAM ball on the back, along with the arm and the handlebar mount, but then you have to protect the Nuvi from the elements. Hope that helps...! :ricky

  11. Wansfel

    Wansfel 50+ yrs on 2 wheels

    Joined:
    Sep 10, 2009
    Oddometer:
    1,558
    Location:
    Bitterroot Valley
    Got a few miles on the KLR with the Mikuni now. Won't go back. No more top end power, but the throttle response is great. And the ease of access to change the needle setting or main/pilot jets totally blows away the CVK. Fred started listing his plug-n-play Mikuni/KLR kit at Arrowhead Motorsports today.

  12. KamikazeKLR

    KamikazeKLR Shorty on the 650

    Joined:
    May 1, 2012
    Oddometer:
    685
    Location:
    Winnipeg, Manitoba
    It does, thanks. I have zero experience in this field.
  13. 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!
    Yea buddy... I'm gonna have him send me one and either put it on after Labrador... or... before?!?!?!? Though would rather use it around here fopr a few hundred miles first.:deal
    Thanx for the update :clap
  14. WildmanSam

    WildmanSam Adventurer

    Joined:
    Feb 5, 2013
    Oddometer:
    98
    Location:
    Woodstock, GA
    changing out my handlebars turned into a very involved/expensive experience for me.

    i ended up getting heated grips and decided to re-do all my wiring while i was at it...

    no before pic but it was pretty rag-tag; lots of electrical tape and wire nuts :evil

    everything is now heat-shrink-ed and tie-wrapped on the USA made waterproof toggle switches. one for aux power (powerlet receptacle and usp charge port) and the other for the 10w leds.
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    new terminal block to clean it up.
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    wire bundle for heated grip rocker switch ran.
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    rocker switch shown on bottom left. the hole i plugged above it was for a running LED but i melted it while soldering my lead wires to it... combination of large wire, small led and high temp iron... so for now i'll just remember to turn it off.
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    i replaced my old 12v cig plug with a powerlet and had to plug the 3/4" hole with a stainless KO seal, then drill it out to the right (metric:huh) size for the powerlet.
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    wired up. the butt splices will be for the USB plug that hasn't gotten in from fleabay yet.
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    cable management on a KLR kinda seems like an oxymoron.
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    on to the actual handlebars... being a wireman by trade, i use a lot of expansion anchors. the ones that came with the barkbusters looked out of a playschool set. i knew they wouldn't hold up to how often i lay her down so i tapped out bars and installed M8 inserts with loctite. (i couldn't find my red)
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    barkbusters installed. i didn't cut the ATV high bars shorter and had just barely enough room to put the clamp below the cross bar brace. i also put on a protaper clutch assembly. i bought a moose racing mirror mount that was supposed to clamp onto the assembly but it didn't fit the protaper model. I'll probably end up buying a u-bolt and mount it in true KLR fasion.
    [​IMG]
    i also had to trim a little bit of the plastic guard to fit in front of the reservoir
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    and finally i installed the soft bags from HT. the mounting "pucks" they supply are crap. they don't hold worth a crap on the round SL racks. i ended up using 1/2" EMT straps and was able to use the pre-cut holes except for just one where i reluctantly used a puck. (they don't have a big enough lip to fit over the bars).
    [​IMG]
  15. 2whlrider

    2whlrider Adventurer

    Joined:
    Apr 15, 2010
    Oddometer:
    1,010
    Location:
    Manitoba....for now.
    I just got progressive fork springs for my 2010 KLR and can't find information on how long the spacers have to be. Do they have to be cut down from stock length and if so does someone know the length? The instructions that came with the springs are not clear.
    Also, I am changing the fork oil so do I use the factory amount of oil?
    Thanks much for any help.
  16. KustomizingKid

    KustomizingKid Been here awhile

    Joined:
    Nov 21, 2012
    Oddometer:
    679
    Location:
    Minneapolis
    So which project should I start on first... Skid plate/tool box, luggage rack, or rally fairing?

    It's gonna be a busy summer :D
  17. beemerjim

    beemerjim Been here awhile

    Joined:
    Jun 26, 2008
    Oddometer:
    449
    Location:
    w mass

    I used 2" spacers I cut from a piece of nylon rod. You measure down from the top to get the right amount of oil. Go to marknet.us. There is a detailed set of instructions there. Lots of other good info there too


    Jim


    .
  18. Dusty_Bottoms

    Dusty_Bottoms Adventurer Ordinaire

    Joined:
    May 8, 2011
    Oddometer:
    862
    Location:
    Fort Collins, CO
    Rally fairing? Is this something you're fabbing?
  19. KustomizingKid

    KustomizingKid Been here awhile

    Joined:
    Nov 21, 2012
    Oddometer:
    679
    Location:
    Minneapolis
    I am going to do a nav tower with two projector beams and a custom fiberglas fairing that snugs up to the ims 6.6 gallon tank.
  20. jeepsandbikes

    jeepsandbikes loneadventurer

    Joined:
    Aug 16, 2011
    Oddometer:
    154
    Location:
    Toronto
    Today i continued to go through all the bolts on my bike and replace them with stainless hex bolts ..Im trying to get all the fasteners on the bike the same for ease of removal and cut down on tools required , and in some spots T-handle bolts so i dont need tools at all .
    Im waiting for a bunch of stuff in the mail , from a nice aluminum rear master , aluminum pegs , handle bar mirror clamps to mount my license plate and stash box to my rack and a kick ass LED headlight . Im still waiting to hear back from a guy who has a klr600 axle set and kickstand to shed a bit more weight ..
    I still have to install my LED spot lights and switches but i think i want to sell my highway bar and make a new one from aluminum .
    does it ever end ... :eek1