KLR back from the dead? Hopefully, yes.

Discussion in 'Thumpers' started by Kawidad, Jun 19, 2011.

  1. Kawidad

    Kawidad Long timer

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    I've been looking for a KLR for a while now.

    http://www.advrider.com/forums/showthread.php?t=689739

    I wanted to get a project bike (I do this as a hobby, actually addiction is a better word). So, I combined my 2 desires and have acquired a very sad 2000 KLR650. It is truly a sad little motorcycle. It was crashed about 3 years ago and shortly thereafter the PO parked it under a pole barn and left it to rot. I got an okay deal, but not smoking; however, time will tell on how good of a deal or not.

    The crash damage appears to be light. The biggest thing I can see is the frame is cracked right in front of the mount point for the sub-frame assembly. The crack is hairline and does not appear to be serious. I think a skilled welder (not me) could take care of it with relative ease. I also think the sub-frame itself is slightly bent sideways. However, it's so slight that further inspection and dis-assembly is required.

    The bigger issue is the weather damage from sitting uncovered exposed to the elements for 3 years. Fortunately, it came from a dry climate, so I hoping that will also be minimal.

    I just got it, so I don't know where it all stands right now. The PO said it ran fine when he parked it. He just got tired of it and drank some orange koolaid :D (that he ended up hating).

    My goal is to assemble a bike that I can ride the TAT or Great Divide Trail on, with comfort. Time will tell all.

    I'm not much on build reports, so I'll try, but it might be thin. I'll try to keep progress posted as I go.

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    #1
  2. marksbonneville

    marksbonneville Been here awhile

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    Does not look to be in bad shape, I look forward to the build report and lots of pics, I'm ready for another fun project myself.
    #2
  3. NCJ

    NCJ Long timer

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    :lurk
    #3
  4. Kevinhooa

    Kevinhooa Pitch pine slalom

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    +1 :lurk
    #4
  5. Kawidad

    Kawidad Long timer

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    Here's some more pictures of the before, including a close up of the frame crack. Welding advice will be accepted. :D I don't weld, at least not well, so I will have to take it to a pro, so I'm more than open to tips, things to look for, or techniques, etc. :ear

    [​IMG]

    This is a scuff from the crash that damaged the frame.

    [​IMG]

    From what the PO told me, he rode the bike like a motard in some curvy stuff. He laid it too far over on the left side, caught the peg (which broke), flipped him off and over. The bike came down onto the right side and slid to a stop. The bike had/has soft luggage racks (unknown make) and that protected the side panel and muffler, but I also suspect it was so stiff that it caused the impact energy to be transmitted to the frame mount point. :dunno

    (He wasn't hurt, dusted himself off, and kept riding. He didn't find the frame damage for some time and only when he took the tank off for maintenance.)

    The total damage from the crash appears to be both rider foot pegs, water pump cover scrap, ride side passenger foot peg, bent handle bars, scraped throttle tube, frame crack, and slightly bent sub-frame. All in all, the damage doesn't look that bad considering how hard it must have hit the pavement.:deal
    #5
  6. Airvent

    Airvent Been here awhile

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    Hey! It came with a free spider :lol3 Good looking project bike. Looking forward to updates.

    [​IMG]
    #6
  7. Kawidad

    Kawidad Long timer

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    Lots of spiders actually. I had to spray with bug killer, let it sit overnight, spray it again, and then pressure wash it.:eek1
    #7
  8. AfricaWim

    AfricaWim Been here awhile

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    Appart from sun damage on the plastics it does not look bad at all.
    I had a cracked subframe that I took a guy I know who runs a custom exhaust place. He cut a "V" in the crack, welded it, cleaned the weld and after spraying the frame you cannot even see it.
    #8
  9. LndCrsr

    LndCrsr Adventurer

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    How many miles showing on the odometer and if you don't mind sharing, how much did you pay for your new project?
    Just curious...also, did you get anything else in the deal? Accessories? Farkles?

    Thanks for sharing and good luck!
    This could be good and I'll be watching.

    Cheers! :freaky
    #9
  10. MotoBoss

    MotoBoss Bad Influence

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    If it was me in that condition I would just part it out.

    Oh and I would buy the side covers for mine from you:lol3 :lol3




















    just kidding.........................fix it and ride it. but I need those covers :evil
    #10
  11. techforlife

    techforlife CDI REPAIR

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    Sweet.i like a good build.........:deal

    :lurk


    B
    #11
  12. RevBill

    RevBill Irreverent Reverend

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    .. love to see a good resurrection ..
    #12
  13. Gray_Rider

    Gray_Rider Been here awhile

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    That frame crack is quite a common problem on KLRs. It is not likely to have been caused by the accident but more likely by being overloaded with rider, passenger and luggage then ridden over a bad road.
    #13
  14. bigdon

    bigdon Long timer

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    My plastic looks like that and I ride it everyday! Add a few stickers, kind of like lipstick on a pig!
    Check the battery, clean the carb, weld the frame, add fresh gas , ride the crap out of it! Well you may want to fix the foot pegs. :lol3
    #14
  15. Kawidad

    Kawidad Long timer

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    It came with SS brake lines and soft luggage racks. Otherwise it was bone stock with 29k on the clock. It even had the Kommiefornia smog junk still in place.:puke1 The PO said he was the second owner and had it for some time. He didn't believe in the hoopla about the Doo, so he didn't do it. Well, it cut loose and did some damage. He repaired it and replaced the Doo.

    I over paid, but it is, what it is. $700. :bluduh BUT, if all I see so far is wrong and there are no hidden surprises, then I did okay.

    Thanks Brian for checking in and others for the encouragement.


    Here's a couple of pictures of the after clean up with the pressure washer.

    (Still finding live spiders :huh)

    [​IMG]

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    No bad so far. The battery is completely toasted and I found an old mouse nest in the airbox. Fortunately, the mouse chewed into the air filter, but not through it.

    I pulled the spark plug and it's burning a little rich, but otherwise looks good. I assume that is from the completely clogged old and nasty stock air filter (probably original). The radiator/anti-freeze looks good, no choco mess. I drained the oil and pulled the filter. I examined both carefully and they looked great. The filter especially looked surprisingly good and clear of debris.

    I pulled the carb off and took it apart. It was really good and clean. He left the inlet hose off and it was completely clogged with mud :yikes but that wasn't a bad thing, in that it formed a barrier and protected the internals of the carb.

    More to come...................:deal
    #15
  16. MotoBoss

    MotoBoss Bad Influence

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    :thumbup Keep it up. Looking good. A little maintenance and TLC and your ready to go, them let the farkeling begin.
    #16
  17. live2offroad

    live2offroad Been here awhile

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    in.. I love a good "back from the dead" story..
    #17
  18. Kawidad

    Kawidad Long timer

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    Okay, so I got the bike clean enough to work on some more and to attempt a start up. I bought a battery, new air filter, and oil/filter. However, before I attempted a start up I decided to take the air box off and clean it as completely as I could, since it has some weird bends and nooks and crannies. I wanted to make sure I got all of the mouse crap and bedding out.

    Once that was done I tried the gas tank out only to find the petcock was leaking fuel like a sieve. I pulled the petcock apart and replaced the 2 o-rings from a Harbor Freight o-ring kit I had laying about. Not a perfect fit, but it seems to work. I kept the vacuum operation part intact for now. However, I plan on getting a plastic gas tank to replace the dented metal one. I also happen to have a stock petcock from a Yamaha WR400, and it lines up perfectly, so that's what I'll use when the time comes.

    So, I bolt on everything necessary for a start up. Put the key in and crank.

    The engine rotates and everything sounds okay, but no start. :becca I crank it and it sounds like no compression at all. WTF? :dog

    I check the spark plug, and it's getting a good looking spark. I then crack open the carb float bowl drain plug, and fuel spills outs. No problems there.:hmmmmm

    So, I think through all of the possible diagnostic stuff and talk to my m/c mechanic buddy for suggestions and we both agree that the only thing to do next is pull off the valve cover and have a look, since it's getting fuel and spark.

    I pop off the valve cover and I immediately can see the valves are set too tight. I then check it with a feeler gauge and I can't even get a feeler gauge in. :doh

    Problem found, now I just have to re-adjust the valves. However, I have to check with my buddy to see if he has shims that I can use/trade.

    Of course, this brings me the conclusion that the PO lied and the jackass did not just park it. There is no way it was running after the valves were set like that. It seems more logical he tried a valve adjustment himself, screwed it up, killing the bike, then didn't bother to correct his mistake, and walked away. Hopefully. Since he could have done way worse, which may be to come, but again, hopefully not. :deal
    #18
  19. RevBill

    RevBill Irreverent Reverend

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    .. ahhh .. a twist in the plot .. good detective work ..

    .. getting juicy now ..

    .. edit .. oh yeah .. when referencing "finds" like that, "he whom did such things" is usually referred to as the "DSPO" .. you are being to kind .. though it could have been an honest mistake, he didn't fess up ..
    #19
  20. griffo1962

    griffo1962 Long timer

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    Let's hope he didn't bend any valves after his valve adjustment mistake.... check the cam timing very carefully..:evil
    #20