KLR650 Only Thread......

Discussion in 'Thumpers' started by willys, Nov 19, 2011.

  1. GreatWhiteNorth

    GreatWhiteNorth Long timer

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    Thought I'd share this... Today I installed an LED tail light (the LEDs on a circuit board set-up), and an LED strip type trailer light (mounted to thin L angle aluminium) on to this Gen 1 I'm fixing up (the salvage yard special :^) The HID lights in that Britannia Composites fairing are very bright and white. The license plate light is LED too. What a major upgrade over stock lighting. I'll be adding two aux lights up front as well (see and be seen).

    IMG_20171002_1957231.jpg
  2. Tweakedlogic

    Tweakedlogic Adventurer

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    Just saying, I've been using different forums for a long time. Never seen one lump everything together like this in one thread. It's always been sub forums. Which has the benefit search by title in case I need to find threads related only to wiring, custom port work, parts for sale, or just pic threads, etc. It also makes it easier to browse when I don't know what I'm looking for.

    And yes, it's been a long time since I've been on. 3 years ago the wife got knocked up and I didn't have an adv bike. Now I have one, the kid is a bit more independent, so I've been dreaming, planning, and researching. I wasn't trying to come off as a dick. Just un-requested $.02
  3. GreatWhiteNorth

    GreatWhiteNorth Long timer

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    You've got a valid point, and it's been brought up before. I'm guessing those "other" forums are KLR specific? When the site admin changed over the forum engine to this one (XenForo/Waindigo or whatever it is), the search feature become much better. It's not perfect, but it's better than it was.
  4. Tweakedlogic

    Tweakedlogic Adventurer

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    Varied... vintage motorcycle, 4x4 trucks, my RX7, bees, wood working, cafe racers, bicycles, contractor forums, beer/wine making. I'm into different stuff.
    Most follow the format i described. This way is a little weird to me.
  5. GreatWhiteNorth

    GreatWhiteNorth Long timer

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    Before the forum engine was changed, you could only search within a sub forum (like thumpers)... now at least you can restrict the search to "this thread only", a huge improvement. Lots of good info in this thread... just gotta dig for it.
    thechief86 likes this.
  6. Grinnin

    Grinnin Forever N00b

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    A larger front sprocket certainly should wear that sprocket and the chain slightly slower.

    I read the request for recommendations as a rumor that a larger sprocket shortens engine lifespan not chain lifespan. The engine is certainly working harder with a larger front sprocket. The request wasn't clear on what lifespan shortens and my response wasn't clear on that either.
    Another thought on chain life and sprocket size. Larger sprockets can also decreases the maximum tension on the chain -- the chain is being pulled by the same shaft torque, but the torque is reduced by the longer "lever" that the shaft has to pull. Works for engine braking too since the maximum amount of braking is controlled by the engine. These probably don't translate into decreased chain wear since we don't usually ride at maximum torque and it just causes riding in a lower gear. If you think I'm wrong, corrections welcome. I DO think the affect is minimal.
    GreatWhiteNorth likes this.
  7. Mayomoto

    Mayomoto Ultralurker perman00b

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    Interesting to see this as the last post after spending the last 6 months reading this thread. The whole is more than the sum of its parts said a dead greek dude, and that certainly applies here. Individual opinion validated through dialog and debate. The path to truth.

    I see this sentiment often when lurking these megathreads, people bitching about not being able to instantly access the precise information they seek. I would wager most of the inmates posting on this board are in the demographic that still realizes the miraculous absurdity of having the sum total of human knowledge at your fingertips. Ya'll remember some bullshit called the Dewey decimal system?

    I'm desperately trying to teach my young racer the pitfalls of information acquisition. He runs with the first thing google spits back at him. All he has done is selected a single random voice from a cacophony of idiots. He wanted to learn about motorcycles, so I got him a job sweeping floors and changing oil at our local independent moto shop. There is no free lunch, you gotta work for it.

    About 7/8ths of my way through this thread, I figured I had a handle on things, so I bought a Gen 1, a '96 with 40,000 miles on it, took it apart, put it back together, and rode it to Idaho and back, 10 days 3500 miles, no motels. First overnight moto trip, anywhere, on a machine old enough to vote and drink. Very little prior mechanical experience. Only because of the contents of this thread, in its entirety, and others like it was I prepped (mostly) right and carrying the (mostly) right shit to get me there and home again.

    Available here, if you put in some time, is a free Ph.D. in KLR. Thanks ya'll, I couldn't and wouldn't have done it without you.
  8. GreatWhiteNorth

    GreatWhiteNorth Long timer

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    "... rumor that a larger sprocket shortens engine lifespan not chain lifespan" This guy seems to think so:
    http://www.topgunmotorcycles.com/cp_archive/cpjun07.html

    If the engine is working harder being geared taller, I'm thinking the load must go up. Big difference tho IMO between a stock engine with 36 hp vs an engine that's been hopped up a bit with big bore piston, intake & exhaust mods, etc., and is producing more power. The more powerful engine would pull a taller gear easier.

    I like the point in that article "If you really have to ride on the freeway at 80+ mph, you probably should find the proper tool for the job and buy a different motorcycle."
  9. Tweakedlogic

    Tweakedlogic Adventurer

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    So I'm looking for a used rear shock for my 03. The stock one is painfully inadequate, as is the contents of my pocketbook. I can't justify spending $700+ dollars to me, much less my wife.

    Anybody have a good used shock?
  10. HardWorkingDog

    HardWorkingDog Harvey Mushman

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    Most economical way to improve the existing shock is to rebuild the internals and replace the existing spring with one that's suited to your usual riding style and load. rockymountainatvmc.com has some great DIY videos on rebuilding the KLR shock, along with all the parts needed.
    Tweakedlogic and thechief86 like this.
  11. thechief86

    thechief86 Been here awhile

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    Ok fellas, I'm set to pick up my next KLR, a 2008 a week from today for very cheap. The current owner says it wont start, due to low compression, and suspects bent valves.
    I haven't asked how he came to these conclusions, but I'm going to ask today.
    I'm thinking if he believes this to be the case, it must have been underwater or something.
    I'm hoping i can get away with just swapping on my spare head, but what else would you guys suggest I check out before getting that deep into it? Maybe spin the motor with the valve cover off and watch?
    The bike is a stock 2008 with 23k miles

    EDIT: the guy sent me this photo of what he found when he removed the valve cover.
    Is this evidence of a seized or bent valve?
    IMG_0906.jpg
  12. John Fry

    John Fry Adventurer

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    My bad.
    It was my understanding of what I read somewhere that changing the teeth count changed the number of contacts between chain and that increased wear on chain and the sprocket.
    It was mentioned that it would increase stress on the sprocket shaft as well.
    That was why it recommended changing the rear sprocket. To spread the increase over a bigger diameter.

    That said, it seems likely that it was referring to decreasing the teeth count. Lol

    I know so little about this stuff.
    Heck, I'm not even sure if I need a different size chain if I change sprocket size.
  13. nvklr

    nvklr Been here awhile

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    You can go up at least one tooth on the front sprocket without changing the chain size, not sure if you can go to two more. (Stock is 15 teeth) in case anyone reading this didn't already know that.
  14. Pollack

    Pollack Adventurer

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    You can go to a 17T with no problems.

    Best regards,
    GreatWhiteNorth likes this.
  15. Magwood1425

    Magwood1425 n00b

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    Does anyone know the length of a stock clutch cable for 2016 KLR? I want to raise my bars by about 4-5 inches and will need custom cables. Galfer or Motion Pro or someone else?
    BigFatAl likes this.
  16. BigFatAl

    BigFatAl Been here awhile

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    I raised mine about 4" and did not need a longer cable BUT I used narrower bars so that helped.


    Sent from my iPhone using Tapatalk
  17. GreatWhiteNorth

    GreatWhiteNorth Long timer

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    Yup. That head is toast. Do the 685 cc kit upgrade, get your spare head refurbished and bolt 'er on, and you're in business.

    Bent valve could have happened in a few different ways. It doesn't look like it was run low on oil tho, as I don't notice an aluminium debris pushing out from the sides of that broken cam bearing journal cap. Could have been over-revved and valve float resulted in valve contacting piston.

    I'd posted this waaay back in the thread, but of course many of my earlier pics are gone because of the Photobucket fiasco. This head came off a KLR that I bought at a salvage yard. It was an oil burner, had been run low on oil, galling the RH exhaust cam bearing. The metal debris seized the bucket in it's bore, resulting in valve contacting piston (bent valve). It spit the shim out, got jammed, and cut the KACR off the end of the cam. Must have made one heck of a racket as it groaned to a halt. How's that for a catastrophic failure! I put a new piston in that engine, and a different head, ran fine.

    WP_20160323_002.jpg
    thechief86 likes this.
  18. thechief86

    thechief86 Been here awhile

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    Thanks! I may inspect the piston and cylinder and just swap the head if it looks ok. I don't have the money to do the 685 kit at the moment. Although I guess I could just ride my dr350 for now and try to go big bore over the winter.... I'll just have to check it out.... if I'm able to use the 2008 case, would it be worth the time and effort to remove the doohickey and torsion spring from my spare '89 case and stick it in the '08? I know they upgraded that part in '08.....
    Also, is there any reason I shouldn't use the head and cams from the 89?
  19. Aprilia

    Aprilia Long timer

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    Do not swap over the stock 89 Doo and spring. 89 head you must include the stock valve cover. 89 has better cam profiles over a gen 2.
    thechief86 likes this.
  20. GreatWhiteNorth

    GreatWhiteNorth Long timer

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    A budget fix would be to get the cylinder lightly re-honed, removing minimum amount of material, and re-ring the stock piston with these higher tension rings:

    WP_20160423_008.jpg
    thechief86 likes this.