KLRsys build

Discussion in 'Some Assembly Required' started by KLRsys, Jun 6, 2012.

  1. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    I fixed the picture link above, here it is again.

    Pictures
    #21
  2. elgato gordo

    elgato gordo KTMRFS

    Joined:
    Oct 7, 2007
    Oddometer:
    512
    Location:
    ABQ, NM
    Thanks for the link to the pictures. Your build almost makes it look reasonable but it always looks easy after it's done.
    #22
  3. SamM

    SamM Jeep Overlander

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    Nov 1, 2004
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    1,471
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    West Virginia
    Wow, that does look factory made! NICE!

    SamM
    #23
  4. KLRsys

    KLRsys Been here awhile

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    Jun 6, 2012
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    131
    Location:
    Deep south Texas
    I weighed it today. 209lbs rear, 175lbs front, 384lbs total. With almost 1/2 tank of gas. Not bad I think. My 07 weights 432lb but it has panier mounts, crash guards, center stand and a Corbin seat which is quite heavy.
    #24
  5. KLRsys

    KLRsys Been here awhile

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    I thought you had one in the works. I remember seeing teaser pics.
    #25
  6. stefer

    stefer Been here awhile

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    Rolla, MO
    This guy tediously measured his Gen 1 KLR. 411 lbs wet. (full tank)

    If you top er off with 3 gallons of gas at 6 lbs a gallon you are at 402 lbs. Not bad considering the extra power.

    Kudos...good work here.
    #26
  7. stefer

    stefer Been here awhile

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    Also, is the KLR vibration gone?
    #27
  8. KLRsys

    KLRsys Been here awhile

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    The KLR vibration is gone, but now it has the Versys buzz over 4k rpm. Below 4k it's really smooth. All in all, while riding down the highway the general presence of the motor is much less noticable than it was before. At 65mph, the tires make more noise. I like it. Although I like the low noise level of the stock muffler I would like to change it soon for some weight savings, but I don't want it to get too loud. Any suggestions?
    #28
  9. Kawidad

    Kawidad Long timer

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    Jul 9, 2005
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    Central Coast, Cal
    Very nice work. :clap
    #29
  10. Dirt Freeak

    Dirt Freeak Adventurer

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    Jul 18, 2011
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    Mt. Effort Pa
    Nice work.

    Curious if you are concerned about heat soak of the rear shock; the exhaust looks CLOSE (maybe it's just the camera angle?)
    #30
  11. KLRsys

    KLRsys Been here awhile

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    Good point. I've been planning a heat shield for the section of pipe that runs close to my left leg, but it really doesn't radiate as much heat as I thought it might. I'm going to do it anyway. I should probably put one near the shock, the exhaust is about .5" from the spring, about 1" from the shock body. I have a Progressive shock that I'd like to install, hoping it will clear the exhaust.
    #31
  12. WILL_S

    WILL_S OUTLAW POSTIE 001

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    goodly satisfactory place, qld

    Man thats clean:thumb
    #32
  13. dentedvw

    dentedvw Where did I put that

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    ☼SLC-ish☼
    Do I understand you right, you turned the throttle bodies upside down?
    Awesome, I didn't even know you could do that.
    Putting that in my notes. :deal
    #33
  14. KLRsys

    KLRsys Been here awhile

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    The goal was to get the manifolds turned upside down which angled the throttle bodies downward a bit. Turned out having the throttle bodies flipped over fixed a problem where the throttle position sensor was hitting the bottom of the tank. I had to redo the cable mount and make a new bell crank (out of three fender washers) but no biggie.
    #34
  15. thorinoakenshield

    thorinoakenshield ya mo be there

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    Dec 22, 2011
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    Nice job! :clap
    I like this pic:
    [​IMG]
    #35
  16. bearcat1

    bearcat1 Been here awhile

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    Aug 27, 2006
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    Olympia, WA
    KLRsys,

    OK now put the KLR engine in the Versys chassis!:roflSeriously though; Wow, great job on the KLR build! :thumb
    #36
  17. biggyfries

    biggyfries Been here awhile

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    Feb 4, 2008
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    You might consider modifying the stock KLR muffler to remove a little weight and possibly improve flow without adding much noise. Cut off the front "fishbelly" part of the muffler leaving only the stock can, less the inside baffle. You would think that much of a reduction in pipe would make it a lot louder, but it is hardly any louder than stock, maybe just a bit lower in tone. Everyone thinks my muffler is stock until they look under the side cover.
    I'll take a pic if anyone is interested in seeing a smaller KLR muffler.
    #37
  18. KLRsys

    KLRsys Been here awhile

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    I'd like to see a picture or two. I have a spare stock muffler that I can experiment on so I'm interested. Thanks.
    #38
  19. JAFO

    JAFO displaced Jeep guy.....

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    Aug 21, 2006
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    Charleston, SC
    I too would like more details on this can surgery, and this bike build
    #39
  20. KLRsys

    KLRsys Been here awhile

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    Jun 6, 2012
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    131
    Location:
    Deep south Texas
    Sorry, I missed this. What would you like to know?
    #40