The gravel road tourer, my take on the KLR650

Discussion in 'Thumpers' started by fleshpiston, Jan 28, 2013.

  1. Beezer

    Beezer Long timer

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    nice. but as far as swapping forks goes... mebby not worth it. I put YZ forks on mine & ran it for a year. cushy ride but with the fat USDs you lose some travel lock to lock. you also lose the stock instruments, no loss... I kept the Acewell gage when I switched back to the stock forks with Ricor valves. the Ricors in front & Moab on the back fix the ride pretty well... it'll give you everything you need unless maybe you are jumping it. something to consider. in fact I've ridden side by side with my friends 640A & it 's really close... even he agreed, though most orange guys will contend that is not possible and are outraged by the suggestion.
    #21
  2. bobfab

    bobfab Long timer

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    me too!
    #22
  3. fleshpiston

    fleshpiston Been here awhile

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    Now you tell me! :lol3

    You're probably right, I guess I'll find out this spring.

    As far as the steering lock goes.... I've heard people complain about it that have done the swap and I just don't see it as being an issue. I modified the steering stops, which I'll cover in the next couple posts, so I'm only losing a couple degrees of lock. The only time I can see this being an issue is making a u-turn on a really tight trail. If you're doing that often on a KLR you might be on the wrong bike? :dunno





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  4. fleshpiston

    fleshpiston Been here awhile

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    So time to make the gold springy things fit the red shiny thing.


    Time to visit my friend Ted. Ted is equal parts genius and artist. It's good to know people like Ted.

    The Yam steer tube is too short so just swapping bearings isn't an option, the stems need to be swapped.



    so apply a little heat .........




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    Press out the old ..........




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    Here you can see the difference in length.....




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    A spacer could be made to adapt the the pieces but Ted decided to add weld to the tube.......




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    Then turn it back down to the correct diameter on the lathe .........




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    A top spacer was made up......




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    We also machined the bearing land to accept stock KLR dust seals as the aftermarket ones are a joke ........




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    And after a few hours work we end up with this....... all pretty straight forward if you have the tools or know people that do.




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    Thanks Ted! :freaky





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    #24
  5. Cumbacheech

    Cumbacheech XRated

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    You said it right otherwise it can be a real pain... looking forward to the rest of the buildup.

    :lurk
    #25
  6. Rot Box

    Rot Box Been here awhile

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    Cool. Looking forward to updates :evil
    #26
  7. fleshpiston

    fleshpiston Been here awhile

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    Getting back to the steering lock issue....


    My solution was to remove the stock stop on the frame and make one that's compatible with the Yamaha triple.

    This is all hacksaw and hand file (I'm no Ted)




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    I had my bro brass braze it to the frame so it wouldn't distort the head tube with excess heat.....




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    Then I mocked it up with shop vac tubes and checked clearance on the left




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    and on the right ....




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    check it, grind some off, check it again, grind some off, check it again, grind, check, grind, check, etc etc etc





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    As mentioned before I did lose a few degrees of turning radius but I really don't see it as a deal breaker. Only an issue when making a super tight u-turn or maybe when moving it around the garage. Even then, worst case is that it becomes an 8 point turn instead of 6 :dunno


    I actually rode for several weeks with little plastic blocks taped to the stock stops to limit the lock and test it out. Not once did I miss the extra lock.




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  8. KustomizingKid

    KustomizingKid Been here awhile

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    A local guy building a KLR.... I am starting my build this weekend :D
    #28
  9. ProZac235

    ProZac235 Adventurer

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    Awesome
    #29
  10. PWRCRZR

    PWRCRZR Grumpy Old Bastard

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    nice job on the fork swap, having the tools and knowledge to use them are key
    #30
  11. fleshpiston

    fleshpiston Been here awhile

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    So true, so true........ unfortunately I'm a little lacking on both fronts :1drink




    So the forks are on, now what? Well the Yam forks have 11.9" of travel, the rear shock only has 9.1. What to do? I suppose I could have shortened the travel of the forks but instead I gave the folks at Cogent a call to see what the options were. Turns out the longest they can go is an additional 8mm at the shaft (they can go longer but that requires a remote reservoir which is $$$$$$) the 8mm equals about 1.5" of travel at the wheel. Not ideal but should get me in the ballpark and balance things out front to rear. I ordered one.





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    Starting to mock things up......





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    Hard to see here but I removed the side cover brackets (wont be using them) and lower passenger peg brackets just to remove some clutter and clean things up a bit.




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    Just a note about the folks at Cogent...... GREAT service! I was really impressed, spent about 20 minutes on the phone talking about what my goals were, usual terrain, how much luggage, etc. etc. They really seemed interested in what I was doing. It wasn't the usual "Rider weight without gear" and done. I highly recommend them. :deal




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    #31
  12. KustomizingKid

    KustomizingKid Been here awhile

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    I gotta come see this in person... I am living in South Minneapolis off of Daimond Lake.
    #32
  13. East Coast Rider

    East Coast Rider Just Me...

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    Thanks a lot. :bluduh

    Another KLR suspension mod thread. Just what I need! :lol3


    Rick and Joyce (@ Cogent) are absolutely first rate :nod I'm lucky enough to live just a couple hours from Rick and Joyce.

    I'm setting aside funds to put a KX450F front end on mine. and a long travel shock from Rick...I've already sourced a machinist who is well versed with hotrods, mods, motorcycles, etc. Woot!


    This has been bookmarked for future reference!!
    #33
  14. fleshpiston

    fleshpiston Been here awhile

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    Cool!

    Don't forget to budget for heavier springs too. :deal


    Speaking of which.... when trying to determine what rate I needed I went to Racetech's site and entered my weight plus the additional weight of the KLR and 6 gallons of fuel. It recommended .57 kg springs. :eek1 I searched and searched and couldn't find anything close out there. The F650 guys suggested that Cannon Motorsports/House of Horsepower could make a custom set.

    I called them and they said that they could do a straight rate spring but it would be a "busy" ride over small bumps- especially washboard which I see a lot of. We decided to do a progressive rate spring .50 - .58 kg. While on the phone I let them talk me into re-valve too. :lol3

    So my original plan of keeping it cheap went out the window :cry I was just going to crank up the adjusters and maybe even try 7 weight oil but in the end I'm glad I had it done right ..... now I can cross "tune forks" off my list and just ride once the snow melts.




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    #34
  15. fleshpiston

    fleshpiston Been here awhile

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    I got the 89 motor back in, I'll run it while the 96 motor gets refreshed with the 685 kit and mild porting.(and possibly advanced EX cam? :ear)





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    I thought about painting the fairing bright red to match the frame but eventually just went with white.....




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    #35
  16. Kawidad

    Kawidad Long timer

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    DO IT!!!!!:evil
    #36
  17. fleshpiston

    fleshpiston Been here awhile

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    You go first :D




    I finally got to try the stock WR/YZ front brake on a friend's bike last month......




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    Conditions weren't exactly ideal but I could tell it would be lacking with another 200+ lbs to haul down. I went with the EBC 320mm ......





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    I'm sure it's going to be overkill in the dirt but I still commute on the bike where it should come in pretty handy.





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    #37
  18. Beezer

    Beezer Long timer

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    I heard about advancing the cam gear 1 tooth from Eagle Mike. he did dyno on it & says it works. good enough for me. haven't done it yet but I will when the snow melts enough to get to the bikes
    #38
  19. fleshpiston

    fleshpiston Been here awhile

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    Excellent! Looking forward to your thoughts. Are you going to do any dyno time or just "seat of the pants" ? I'm not a member over at .net so any info would be appreciated.



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    #39
  20. fleshpiston

    fleshpiston Been here awhile

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    All right then ...... on to the dash :1drink





    It started out as a humble store display ........





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    It sits a little low but that should keep it well protected from the elements .......




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    I've since replaced the brake line with one that tucks out of the way much better.

    Main power on upper left switch, the lower one with LED is for the heated grips. Volt meter on lower right. Simple!





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    Everybody seems to hook up the Vapor a little differently, I ended up pulling the spades out of the stock 9 pin connector and putting them in the TT 6 pin block. Sorta the opposite of what TT had in mind but it works for me.




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    Turn, high beam, and neutral indicators ready to go......




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    #40