KLR 650 Modifications

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

  1. heffa

    heffa Canyon Hillbilly

    Joined:
    Jan 24, 2010
    Oddometer:
    1,008
    Location:
    PA.
    Thanks Scott, I did miss it. I like the wiring setup. :thumb
    I have always liked the terminal blocks (bus bar). I will be using the wiring idea, once I design a new dash for my mod Fairing.

    Are all the switches and outlets from Radio Shack?
  2. hoyks

    hoyks Tightass KLR rider

    Joined:
    Jan 11, 2008
    Oddometer:
    814
    Location:
    SE Qld.au
    Once I sand it back and see if I can make a clear one out of it easily I might. It was more work than I thought it was going to be.
  3. kens_Moto650

    kens_Moto650 Top end explorer

    Joined:
    Nov 5, 2010
    Oddometer:
    31
    Location:
    Darwin,NT
    Hey all, I've just modified a screen off a ZX6 ninja which I had lying around and thought it would be a good low buck modification. Ive tested it at 130km/h with a dirtbike helmet on and its pretty good. Im 6.0' and it just catches the visor, so if i crouch a little im out of the wind.

    I can see why everyone changes to different screen now.
    [​IMG]

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  4. NDTransplant

    NDTransplant Been here awhile

    Joined:
    Jan 24, 2010
    Oddometer:
    446
    Location:
    Casa Grande, AZ
    That looks nice, Ken. I had a 22" Cee Bailey on '09. It was extremely effective, but huge!
  5. wparkinson

    wparkinson Gear Whore

    Joined:
    Dec 18, 2008
    Oddometer:
    2,071
    Location:
    Down On the Farm...
    You can take a propane torch and hit the edges of the plexie glass and it will give you a nice smooth looking edge.
  6. binskies

    binskies Been here awhile

    Joined:
    Aug 7, 2007
    Oddometer:
    173
    Location:
    Denver
    This is how she looked when I bought her

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    The ding on the tank isn't as big as it looks in the pic. I can't wait to start doing some dual-sport riding.
  7. mikejet

    mikejet KlrKid

    Joined:
    Apr 6, 2008
    Oddometer:
    96
    Location:
    Somewhere in the swamps of Jersey
    Hey all, Here`s a list of what i`ve done ( so far ) on my 2008 Green Machine

    remove clutch switch
    remove side stand switch
    relocated rear blinkers
    mercedes breather valve
    open up airbox
    stainless steel oil filter
    eagle mike doohickey and torsion spring
    added headlight off switch
    12 volt power outlet
    heated gear outlet
    Trax panniers and mounts ( Heavy Duty Man )
    4" tube carrier ( front of frame )
    Aluminum skid plate
    tank bag
    1.5 handle bar risers
    Roo knobbies ( nice! )
    Cee Bailey headlight protector
    Custom fab`d spare tire / crutch carrier ( changing flats )
    Rear master cylinder guard
    Yuasa sealed battery

    Attached Files:

  8. MotoBoss

    MotoBoss Bad Influence

    Joined:
    Apr 15, 2009
    Oddometer:
    4,002
    Location:
    Mid South Indiana
    I can't remember or count all the changes or mods!
    Still digg'n the '98................

    Attached Files:

  9. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    I really thought I had put my bikes in here, but after looking I haven't put either one in. I save you the boring details on my 89' and go straight to the 08. there is too much done for me to remember it all or to list it. If you see something you want to know about just ask. here the high point
    • 705 kit
    • stgII head
    • fmf header w/ leo pipe
    • woody's supe lace wheel set
    • yz250 forks dail in by motocd.com
    • long travel rear shock with 10" of travel and 11" front
    • custom dubble wall skid plate
    • custom side panels
    • H-T elite pannier racks
    • heated grips
    • fat bars


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    windshield mount
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    the elite racks pull the panniers in tight with the frame 7" tetons
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    tail system with 5" panniers
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    with new suspension set up completely bottomed it has 2" clearance
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    home made rad guard
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    plenty of ground clearance
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  10. bete

    bete misguided adventurer

    Joined:
    Mar 22, 2008
    Oddometer:
    587
    Location:
    kansas Flint Hills
    Hey John, thats a sweet set up KLR. I'm getting ready to do a big bore because mine is suckin the oil, Do you think theres a big diferance between the 685 and the 705? did you go with larger valves and porting? stock cams? thanks, bete.
  11. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    actually there is a difference and it is felt in the lower end and midrange performance. Seems to be the same up top. I had the 685 and STGII head before going to the 705 kit.

    the heads are ported with polished combustion chamber with over size valves. I have not tried cams yet, but wouldn't mind moving the peak torque up 500 rpms. My issue is that no one I have talked with has enough experience with the cams to give me clear advice on what grinds to look for. I would like the same curve just moved up about 500 rpms which would also give me a few extra ponies up top. I am sitting at 45 rwhp right now and it runs nice. It pulls a 17 tooth front well fully loaded
  12. pzs

    pzs Been here awhile

    Joined:
    Apr 30, 2008
    Oddometer:
    210
    Location:
    Central Australia, desert dweller
    What is the benifit to fitting an 18 or 19 inch front wheel on the KLR.
    This seems to be a popular mod on this bike, more so that in any other big singles forums I can see, I
  13. newcastleadam

    newcastleadam Artful Tagger

    Joined:
    Oct 14, 2007
    Oddometer:
    3,465
    Location:
    Gainesville, Fl
    [​IMG]

    The Pig in fighting trim :D
  14. MetalBender

    MetalBender Banned

    Joined:
    Mar 5, 2009
    Oddometer:
    645
    Today I got the 705 kit and stage 2 hot cams ordered. Exhaust and jet kit are done. Looking forward to the results.

    Is there a way to advance the stator? An offset key or cdi that will pick up quicker?

    This is all I've found so far. http://ignitech.cz/english/aindex.htm
  15. ETrider

    ETrider Gawker

    Joined:
    Dec 31, 2006
    Oddometer:
    426
    Location:
    10-ER-C
    The KLR 250 fairing mod. Sometimes less is more. :D





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  16. wparkinson

    wparkinson Gear Whore

    Joined:
    Dec 18, 2008
    Oddometer:
    2,071
    Location:
    Down On the Farm...
    Ok guys.... posted this over on KLR World....I will post it here... Although I am not the first....Here it is..

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    MISC 009 by sky_soldier_82nd, on Flickr

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    MISC 008 by sky_soldier_82nd, on Flickr

    Was a pretty streaight forward swap... I think it turned out pretty good...:clap
  17. nigelcorn

    nigelcorn Wannabe.

    Joined:
    Aug 17, 2007
    Oddometer:
    818
    Location:
    Albany, NY
    Hmm, I haven't heard of this one yet. What is the benefit of putting the '08 swingarm on the previous gen?
  18. wparkinson

    wparkinson Gear Whore

    Joined:
    Dec 18, 2008
    Oddometer:
    2,071
    Location:
    Down On the Farm...
    Well... for one... Better rear brake... Cleaner look... Who cares.. I got bored...LOL:rofl
  19. johnwesley

    johnwesley wanta be

    Joined:
    May 11, 2006
    Oddometer:
    1,643
    Location:
    mena, Ar
    it should also be more rigid as is a d shaped arm as compared to the square
  20. wparkinson

    wparkinson Gear Whore

    Joined:
    Dec 18, 2008
    Oddometer:
    2,071
    Location:
    Down On the Farm...