Sold my GSA and am back on a KLR !!!

Discussion in 'Thumpers' started by GAS GUY, Sep 23, 2012.

  1. DirtDad

    DirtDad Green Chile Guru

    Joined:
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    I got 12lbs for my stock exhaust, on my crude scale. I used a DG slip on, which is no where near as nice as the Leo. It is a little loud, but only 6 lbs. With the JD jet kit, air box mod, and slip on, it really woke up the bike.
    After removing the license plate holder, and hardwar, foot pegs, and lighter handle bars, I lost about 14 lbs total including the slip on. I heard you can save up to 7 lbs using a lighter battery. That would be around 21 lbs total.
    I noticed the difference with just the 14 lbs.
  2. GAS GUY

    GAS GUY MILE EATER

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    Location:
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    I made up a aluminum plate and a gasket to eliminate the vacuum diaphragm assembly.

    [​IMG]
  3. Adv Grifter

    Adv Grifter on the road o'dreams

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    This one looked pretty good. The owner/builder used to post here ... probably got run off by KTM/BMW attack dogs who Love To Hate KLR's. :lol3

    [​IMG]

    I think a lot can be shaved off by ditching the stock headlight and all the ancillary parts that support it. This guy did a nice job with better forks and shock too. The build is (I think) somewhere on ADV ... no idea where. Anyway ... just another creative direction to go with the trusty KLR! The bike above was NOT the final version ... it was still in progress.
  4. GAS GUY

    GAS GUY MILE EATER

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    ADV GRIFTER,
    I remember seeing that bike.I think it belonged to Sam M.
    I think he ended up putting a versys engine in it,and then eventually moved on to something different completely,IIRC.
  5. Byork

    Byork Novice

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    Gas Guy or anyone else listening,

    I tried to search to find answers, but seeing as I am in the middle of doing the doo I'll just ask. Sorry if its redundant. (I'm asking on this thread because I find it better than any of the "KLR mod" threads. Good job Gas Guy!!)

    I am upgrading to a torsion spring. I removed the stock extension spring without removing the inner case. Since the torsion spring goes outside the inner case, do I still need to remove it for anything?
    Also, the "lever" that the stock extension spring was connected to is just floating on the shaft. Is this correct, I have basically just obsoleted that part and it remains on the shaft?

    So basically, am I ok not removing the inner case if I've removed the spring? Thanks in advance. Maybe I can wrap this up tonight and move on to putting on my new chain.

    BTW my stock spring had plenty of tension and travel, I almost closed it back up without changing it.
  6. GAS GUY

    GAS GUY MILE EATER

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    Oddometer:
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    The factory spring lever does stay in place as it acts as a spacer to keep proper endplay.

    You should be good to go, just try to catch all the debris as you drill the hole, keep it out of the engine.

    I didn't pull my inner cover either when I had to redrill the hole and install a new spring.

    Did you need the Deep Hole spacer ??
  7. Byork

    Byork Novice

    Joined:
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    Oddometer:
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    Hey thanks for the response! No Deep Hole Spacer needed.

    I will drill the hole and start assembly. Just wanted to make sure I wasn't skipping something critical by taking a short cut.

    Thanks for all your detailed projects too, every time I read them it makes me want to go tinker on stuff in the garage
  8. GAS GUY

    GAS GUY MILE EATER

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    I've been kind of busy lately, plus hunting down parts, and playing with some shock ideas.

    Been putting together some fittings and such, and mock up mounting of a reservoir.

    Its still in the works but here is a teaser picture.

    [​IMG]
  9. GAS GUY

    GAS GUY MILE EATER

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    I already have the thermo bob system on the bike so I ordered the temp gauge overlay that is made of Lexan from Watt-Man.

    [​IMG]

    It is nicely made and will be interesting to actually know what temps I am running.
  10. GAS GUY

    GAS GUY MILE EATER

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    Here it is installed.Much nicer !!

    [​IMG]

    If you haven't been to Watt-Man.com, he has some very interesting technical articles on the Klr you may want to read.

    Top notch service also and very fast free shipping.The Lexan overlay was $19.00.
  11. Murphy Slaw

    Murphy Slaw Long timer

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    Very sharp.....

    :clap
  12. Byork

    Byork Novice

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    Looks Good!
  13. Adv Grifter

    Adv Grifter on the road o'dreams

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    I've not heard much about Fox shocks. What's the latest skinny on them?
    I know for the last 15 years seems they've been more involved with bicycles than motorcycles.

    How does the Fox shock compare with the competition? Price?
    (Wilburs, Ohlins, Progressive, Cogent, WP, Hyper Pro) .

    I have an older Ohlins on my DR650 ... a huge improvement both ON and OFF road.
  14. GAS GUY

    GAS GUY MILE EATER

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    I am using the stock shock, and adding a Fox remote reservoir.

    Yeah, unfortunatly Fox got out of the motorcycle shock business, to a lot of peoples dismay.
  15. Adv Grifter

    Adv Grifter on the road o'dreams

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    Don't despair ... because (as I'm sure you know) several other companies are now making shocks for the KLR. I think Ohlins might have something with their latest generation of low cost shocks.

    Also ... I'd bet there are one or two shock guys who can rebuild your stock KYB and make it magical. Not sure, but Cogent Dynamics does a number on the DR650 KYB unit and turns it into a Rolls Royce. Not cheap ... but cheaper than an aftermarket shock. Perhaps Cogent can do the KLR shock as well .. if they don't already? :clap
  16. GAS GUY

    GAS GUY MILE EATER

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    My shock already has a modified 2 stage valve stack from Sasquatch suspension.

    Yes, Cogent offers a Moab shock for the Klr, I had one on my 2003.

    If I ever spend the money on a high dollar shock, I would have Penske build it for me.

    I had them on my GSA and they are impressive and you get a full service and parts manual with it, and are advertised as owner rebuildable.
    You can call them up and order parts or ask them tech questions and they are glad to help you.

    The powersport shock division of Penske is called Custom Axis.

    They will build what ever you want for anything.You can even print off a order form from there website and fill in all the dimensions.

    My buddy still has his on his GSA, and he has about 60,000 miles on his Penske shocks.We have gone 25,000 miles on the fluid and it was like new when we changed it.

    Also, Penske offers a Quad Ring seal for the shaft seal if you want it instead of the normal O-Ring.We went to them because they last much longer before leaking.

    We also put these Fox reservoirs on his Penske shocks front and rear on his GSA and he really likes them
  17. GAS GUY

    GAS GUY MILE EATER

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    I had a little time today to work on the reservoir plumbing and initial fit.

    [​IMG]
  18. GAS GUY

    GAS GUY MILE EATER

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    [​IMG]

    First I had to remove the stock schrader valve at the top of the shock where the nitrogen normally goes.

    Then I opened up the hole with a 21/64 drill bit and retapped the hole to 1/8 npt (pipe).

    Then I installed a brass 90° street elbow (extra long 1.19") which are pretty hard to find locally, but I found them online at Vulcan Lighting.

    The female 1/8 opening then accepts the non swivel end of the hose that was supplied with the reservoir.

    Keep in mind I am plumbing this so I can use the supplied line.

    Of course there are different reservoirs and ways to plumb the system available.
  19. GAS GUY

    GAS GUY MILE EATER

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    [​IMG]

    The swivel end of the supplied hose is a -5 AN and the hole on the reservoir is a 1/8 npt.

    So I needed a adapter for that as you see in the picture.(One end of the hose needs to be swivel so you can hook it all up properly.)

    If I was to make a new hose, I would use -6 to 1/8 npt because nobody caries -5 stuff anymore, but for some reason my supplied line was -5.
  20. GAS GUY

    GAS GUY MILE EATER

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    Here it is dry fitted on the bike.

    [​IMG]