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
    One nice change to the 05, I moved the cruise control controls to the right side switch housing. Used some small Radio Shack switches. Toggle for on/off, black is resume, red is set. Much easier to reach.

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  2. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    4,581

    i see you're using a slightly modified Versys wiring harness, it looks about 6" shorter than the OEM version.

    thanks again.
  3. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    So does the man have a serious eye for the details or what! Of course looking at his bikes, you know he does. I stand corrected, I use almost all of the Versys wiring harness.

    You're most certainly welcome and thanks for the info on the paint.
  4. thomas.tc.young

    thomas.tc.young Been here awhile

    Joined:
    Sep 23, 2010
    Oddometer:
    862
    Location:
    NYC
    you make me jealous klrsys, with job hunting and crappy part time work i never find time to even begin to work on my versys/klr.
  5. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    Finally started making some real progress on KLRsys II. Never can get much done at year end. Spent a lot of time hand making motor mounts.
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    On Jan 14<SUP>th</SUP> it looked like thisÂ…

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    Three evenings later the frame is tacked up and four of the six mounts are in.

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    I wanted to reroute the exhaust to better clear the left front motor mount so next I made the header pipes. Took this pile of stainless tubingÂ…

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    And made some pipes.

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    Today I'm at this point, ready to clearance the gas tank, finish the exhaust and start on the radiator mounting. On this bike it looks like I can use the Versys radiator. On the first bike I had to use the narrower EX650 radiator.

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    I'm hoping to ride this thing in early March.
  6. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    5,333
    Location:
    Sunshine coast qld
    Nicely done

    Love the exhaust.
  7. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    I am with Joe.
    I love the fit and welding on that exhaust. Looks great. It MIGHt, just maybe have a bit too much back pressure the way it is though... :lol3
  8. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    Yeah, the back pressure is an issue but the spark arresting qualities are great! :wink:
  9. Ridin'nFishin

    Ridin'nFishin Real Rider

    Joined:
    Apr 18, 2009
    Oddometer:
    578
    Great build Fritz.
  10. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    Thanks Calvin.

    Tonight I made the radiator mounts. These brackets (hoops?) will also hold other items like the horn, radiator overflow tank and some of the electrics plus brace the lower part of the fairing.

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  11. SuperRio

    SuperRio KLRE650 PILOT

    Joined:
    Aug 15, 2012
    Oddometer:
    13
    Location:
    Victoria bc Canada
    Wow, just wow.... That is coming along beautifully. I think you may need to do my next bike.:freaky
  12. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    Thanks, Scott. I hope to have it ridable by the first week of March. I'm still thinking of heading your way, maybe late May, June?? Don't know what the weathers like up there at that time of year.
  13. SamM

    SamM Jeep Overlander

    Joined:
    Nov 1, 2004
    Oddometer:
    1,471
    Location:
    West Virginia
    Very impressive!
  14. ktmklx

    ktmklx Been here awhile

    Joined:
    Jul 20, 2008
    Oddometer:
    709
    Very nice design work, fab skills and welding. One comment, it looks the the head pipes are touching each other. This could be a problem. Everything moves when the engine is running and under load, the pipes could rub and wear, also could make pretty loud noises as the tubes vibrate against each other.

    Is the pipe set up the same as your other build?
  15. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    Good point. They don't touch until the straight section along the left side of the engine. After I weld on the next section I can tack weld the straight sections together on the back side, that should keep anything from moving.

    The pipe setup is a little different on this bike. On the first bike the left cylinder head pipe was the top pipe as seen from the left and the right cylinder was the bottom pipe. This arrangement interfered a lot with the left/front motor mount. On this bike I reversed it, left cylinder is bottom pipe, right is top. I also raised the frame side of that motor mount about an inch, and now there is no clearance issue. I can pull the exhaust without removing the motor mount.
  16. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    Finally made some serious progress. Not quite two weeks ago Monday I got the frame back from the powder coater. He did a great job.

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    13 days later this is where I'm at. Progress...

    [​IMG]

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    Not quite done but ridable. Needs a skid plate, brake pedal (stole the pedal off the first bike just so I could ride it today, first ride :D), radiator grill, etc.

    A few under the hood pictures...

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    I weighed it before I put gas in it, 387lbs, about 25lbs more than the Gen1 bike. You don't notice it though, I'm guessing because it's a bit lower. I can flat foot this one in regular shoes, can't do that on the other one even with riding boots. The wind protection is better, but the suspension needs work. That's next on the list.
  17. ktmklx

    ktmklx Been here awhile

    Joined:
    Jul 20, 2008
    Oddometer:
    709
    Very nice! Is that a Suzuki 450 fuel pump?
  18. Krasniewski

    Krasniewski I don't ride much.

    Joined:
    Feb 5, 2008
    Oddometer:
    1,264
    Location:
    LA - Lower Alabama
    Wow - such a clean setup. Lovin' all the updates - great work.
  19. KLRsys

    KLRsys Been here awhile

    Joined:
    Jun 6, 2012
    Oddometer:
    131
    Location:
    Deep south Texas
    The housing is, but the pump inside it is from the Versys. I also used the Suzuki pressure regulator.
  20. Ridin'nFishin

    Ridin'nFishin Real Rider

    Joined:
    Apr 18, 2009
    Oddometer:
    578
    Hello Kawasaki, anyone home!

    That is a great looking bike.

    Good job again Fritz.