KLR 650 Modifications

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

  1. Drifter

    Drifter Long timer

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    Aug 28, 2005
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    6,385
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    East of the Sun & West of the Moon
    Hey Gadget Boy! Where did you buy your handlebar risers? and Folding mirror stems?

    Thanks
  2. orklr

    orklr Been here awhile

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    Aug 20, 2006
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    Vantucky, WA
    Thanks! :D

    The lights are PIAA 510s (the newer 510s have a different light cover). The 510s have 55 Watt H3 bulbs. I don't think the stock system will handle them. The 2007 stock stator only 238 Watts or 14V, 17A @ 7000 rpm according to the KLR FAQs page, its close enough to make your butt pucker. Check out this thread tidbits more KLR Fuse block

    You can get 35 Watt H3 bulbs that might work better. My bike is asking for the ESG451 400w stator from Electrosport for Xmas.

    Mounting the PIAAs was easy, I used NOBLE insulated wire clamps (pn 2216) that I had laying around (they are 1/2" w/ 3/8" hole and came in a six pack for $3.99 at Ace Hardware). I'm sure you can find similar clamps at any hardware store.

    Even though the PDs are supposed to be made of 5/8 inch tube steel, I had to wrap a bit of electrical tape around the bars to get the fit I wanted. I wasn't worried about fraying since the insulation on the clamp is rubber. Also, I figure that it will help reduce the vibrations of the PIAAs and their bulbs.

    The mounting bolt of the 510s fit perfectly, but I did do a tiny bit of fiddling with the clamp to get the mounting holes to line up enough to put the bolt through. (The holes didn't line up because to the electrical tape I wrapped on the bars.) Once tightened down, the lights and clamps hold pretty firmly, but you can add or subtract electrical tape to get the fit perfect.

    There were no clearance issues (at least where I mounted the clamps). In the future, I plan on welding tabs onto the PDs and using rubber grommets to help reduce vibrations.

    As far as the switch goes, I purchased a mini-dash from bentspoke. I plan to mount it on that along with a Datel voltmeter.

    Later, I may need more dash space eventually so I've been working on the DIY dash from bigcee. At that time I will probably switch to the Aerostich 5-Function Digital Meter #4632I

    Hope the info helps.
  3. gunny_usmc

    gunny_usmc Semper Fi

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    Eagle, thanks for the lesson, it does help to know the context to use it with, it was something my boy said he heard Mr. Erwin use and I thought it was cool, no disrespect or butchering was intended.
  4. Eaglebeak

    Eaglebeak Aussie BM rider, West Oz.

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    None taken.
  5. irishdec

    irishdec Been here awhile

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    Mar 12, 2006
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    Toronto ,Canada
    Take a look at mine:clap !!!!(no snide remarks)
  6. orklr

    orklr Been here awhile

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    Vantucky, WA
    The merimite containers make me hungry!:dg That's a good idea...I might have to xerox that.
  7. kdxkawboy

    kdxkawboy Mr. NVKLRGirl

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    Dec 25, 2004
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    Location:
    Gardnerville, Nv
    No raising links or any other mods. Haven't had any clearance problems except with the rear of the inner fender. That's why I bobbed the inner fender and moved the plate to just under the tail light. I normally run a 5.10x18 IRC GP1, have had Dunlop 606s and a fat 140x18 Sahara 3. Tire isn't leaving any skid marks on the inner fender.

    One of the other reasons I talked myself into going with the 18", for all the playing around they have done with different size tires/rims on dirt bikes it seems to always come back to the tried and true 18" rear and 21" front. I figured it would just be a subtle difference, like that between normal and USD forks. I was surprised by the difference, which I expect is due to a slight reduction in the fork's rake.

    Oh, I forgot one other mod. I have a dream catcher zip tied to the cross bar on the handlebars. Figure it's a proper adventure rider version of spirit bells.
  8. orklr

    orklr Been here awhile

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    Anyone have a tow hitch setup for the KLR?
  9. Pine Sol

    Pine Sol Been here awhile

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    Jan 6, 2004
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    in transit, without a destination...
    i read alot of people lowering their bikes, but does anyone know of someone making it taller?? i love the looks of desert bikes, and would like to do something similar with my KLR, just wondering if anyone has??? i would like to make raise the front and rear suspension, larger tank maybe a face lift with the speedo clusters wind shield, something like the wind shield off of a 2000 KTM 640 Adventurer, twin head lights would also look good, and see about shaving some of her baby fat off, ie muffler, and other heavy bits.

    i would love to have a seat height of lets say 38+ inches. (alittle bit higher would also be ok)

    any ideas of how to give her this make over???

    thanks
  10. gunny_usmc

    gunny_usmc Semper Fi

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    over at KLR650,com, one of the guys has a hitch on his KLR, towing a single wheel trailer. Looks really good, I'll see if I can find the link to the forum it was on.

    You can get raising links for the klr, try arrowhead motorsports.
  11. JTT

    JTT Long timer

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    Eagle Mike makes raising links too. Arrowhead sells them.
  12. willys

    willys Long timer

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    2,904
    OK...all you guys who have drilled out the slider in the carb to 7/64ths and put the 2 shims under your needle.....what did it do to your miles per gallon rating???? and was it worth it?? Also did you mod the airbox too???
    I am very interested in doing this mod but don't want to kill my mileage to the point that I have to stop at everyother gas station!! lol

    Can someone please chime in and help a newbie out? thanks!!
  13. orklr

    orklr Been here awhile

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    Yeah, I read the info about the Cycle Burro, wish they were still made. I need to fab a hitch for my KLR.
  14. Tazman

    Tazman Tazmanian devil

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    San Martin, CA
    I have never heard of anyone having negative mpg's as a result. I did the mods to the carb, removed the snorkle. did not cut open the air box. and I did drill the slide. I think if I had to do it again, I would shim the needle, remove the snorkle. then ride..... if need be then drill the slide.

    the most important thing you can do is open the pilot screw. start somewhere between 1.75 and 2.0 turns out from fully seated.

    these simple mods will take care of any surging and lean spots in the power band.

    good luck.
  15. CARIBBEANKLR

    CARIBBEANKLR CARIBBEANKLR

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    Hello, I'm tryng to get Raising Links for My Toy, I'm 6'2 and 240 pounds, I really need raise my Klr. May you help me with information about where to buy that links? Thanks, Robert Emeric (Caribbeanklr)
  16. Scotty J

    Scotty J Obedient Consumer

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    Aug 11, 2005
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    I did just about everything I could to mine, except for that badass supermoto setup (holy crap that was bad ass!); Big Gun Exhaust, K&N, DynoJet, heated grips, and half of everything Dual-Star peddles; when I finally threw in the towel. Sold the '03 with 22,000 miles on it for $2475 on ebay.

    I think I recouped only my upgrade investment.

    But back to the topic:
    Of all the crap I tweaked on the bike, the best ones were the cheapest:
    -TWC fuse box relocator
    -TWC fused outlet add-on (I am farkle-boy)
    -Mounting the license plate higher
    -Running a larger fuse for the headlights

    I'm on an Uglysses now, and I'm frickin' lovin' it, but the KLR was my first, and she rocked. She went to a good home.

    Carribeanklr: You want to RAISE it? Who do you think you are, Andre the Giant?
  17. JTT

    JTT Long timer

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    http://www.angelfire.com/ut/moab/parts_frames.html

    Go to KLR...then Suspension...you'll find them about halfway down the page.
  18. klrbaer

    klrbaer Tim

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    Eureka, Illinois
    Sorry to change tyhe subject, but, does anyone know where to find the small (1-2 liter) gas cans that the guys put on there bikes.
  19. Cutter

    Cutter Girivek

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    Lake Winnipesaukee
    The D606's seem to last OK, but are so goddam noisyon the pavement that I can hardly stand it!! Guess I'll try the TKC80's..........I've heard nothing but good about them. But,,,,,,what about noise on the pavement????
  20. orklr

    orklr Been here awhile

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    Maybe your thinking of a 1 gal can like a Blitz?