Yet another KLRE650...

Discussion in 'Some Assembly Required' started by Krasniewski, Jul 27, 2011.

  1. sailah

    sailah Lampin' it

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    I hate to jump on the bandwagon here as a fellow builder but I would second/third what has been said before. Your single backbone frame has been cut in half and replaced with butt welds that look suspect to begin with. I'm not being a critic to pile on, I'm simply speaking as someone who has done quite a few frame modifications.

    I have made mistakes, we all do. I grimace every time I have to pull out the grinder and sawzall and cut off tubing work I spent hours patiently fabricating. But my rationale is my two beautiful children. And wife I guess:evil

    Your lower frame work really needs attention. Not when it breaks, but right now. Find someone with a tubing bender and some 1.25" DOM tubing and make some really beautiful bent down tubes. Best part is no welds other than the top and bottom joints.

    I know you are rightly proud of what you have accomplished, it's not many that come through the other side of a project like yours. And everything else looks great. Just, PLEASE, take care of those tubes before you forget about things and six months later your posting up in face plant.

    If you can't find anyone else local, send me a PM and I'll bend them for you for shipping. But it's much better to have the bike on site to get quality bends.
  2. Krasniewski

    Krasniewski I don't ride much.

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    Kind words and a very nice offer - thanks.

    Taken into consideration - I'll take another look at her with some free time coming up soon. It's just hard to want to change much in that area when I'm actually riding the bike and it seems fine. But I guess that's a poor judge of what's right.
  3. JAFO

    JAFO displaced Jeep guy.....

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    Charleston, SC
    Kras:

    Bear this in mind:
    When you weld, the weldment itself is stronger than the metal you're welding to- BUT- you also retemper the frame and this is certainly NOT a good thing. This is specifically why you want to minimize welds on load-bearing members, and if you must weld you want to reinforce the joint in such a way as the weld isn't taking the load directly. This is why you sleeve a joint when you weld a rollcage if at all possible.

    It's a great build- don't lose sight of doing it right just because you've got some seat time. :)
  4. JagLite

    JagLite Long timer

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    Anchorage Alaska
    Confidence in our equipment is essential to be able to enjoy our activities. :clap


    Can you imagine a skydiver not having confidence in his/her parachute packing?


    A race car driver wondering if the pit crew remembered to tighten the lug nuts as he hits 180 mph??


    But we can be confident and unconcerned about our equipment and be WRONG. :huh






    I am sure this rider was unconcerned about his bike as he practiced his skills.... :1drink

















    [​IMG]

    I think the lack of safety gear attests to his confidence, and/or lack of intelligence :lol3








    Another example of misplaced confidence is this girl:




    [​IMG]


    She is trusting her life to her friend's riding ability to keep her safe.

    Maybe she has ridden with him many times with not the slightest fear.

    Perhaps she has watched him go around this corner again and again before he invites her to ride along.





    However, she should have been concerned.....




    [​IMG]

    Take a look at this picture and what do you see?

    Front wheel has lost traction and they are going down.
    In less than one second they will be sliding on the pavement with the weight of the bike on their left legs.
    Notice her left foot? She has probably lost most of her left toes already and she doesn't even know it yet. :eek1
    This is the small version of the picture, the large image shows her foot clearly twisted sideways on the asphalt.

    Maybe the rider had taken this corner a hundred times at this speed and even faster, so he was confident in his ability to take her for a safe thrill ride. Perhaps he forgot to take into account the extra weight on the rear tire that made the front tire light and lose traction. Maybe he just got on the throttle too soon or too hard. Whatever the reason, the result is the same, blood, guts, gore, and scars for life, at the very least.



    Sometimes there is no warning when things go wrong brother. :cry
  5. Krasniewski

    Krasniewski I don't ride much.

    Joined:
    Feb 5, 2008
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    :snore

    Yeah yeah yeah... thinking about gusseting the front top T until I do major rework.

    Anyway, front sprocket nut is stuck on - not a left hand thread from what I've read. Washer is flat, used a pneumatic impact wrench (could use more air pressure - my compressor sucks), soaked in WD40. I think the previous owner used a lot of permanent strength loc-tite... I applied a bit of heat to the nut as well, but that may have been a bad idea... :eek1

    Anyway - dowloaded the progam for the PCIII - I may play with the maps a bit this weekend. It's been crazy busy at work and at home the last week, but off on vacation soon!

    Bought another stock tank to try to modify similarly to what I already did, but tig it this time and keep it looking better all around. That'll get worked on weeks from now though...
  6. SamM

    SamM Jeep Overlander

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    West Virginia
    WOW! You guys even have me second guessing my build. Part of my plan was to install heavier wall tubing into the downtube and backbone tube on my KLR frame. Honestly, I have always felt that those areas needed to be strengthened as they have been prone to failure. I still feel that it would be better to install the Versys engine into a stock KLR frame. The engine would obviously need to be trimmed in certain areas.
  7. Krasniewski

    Krasniewski I don't ride much.

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    Well - I certainly think that intended use has a lot to do with it... but don't think it would hurt to reinforce the spine - that's for sure.
  8. JagLite

    JagLite Long timer

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    No worries. You can do it!
    It isn't rocket science.
    You just have to do it right.
    Anyone can build an airplane. A homebuilt aircraft is not complex or difficult.
    One advantage of building an airplane is that the builder recognizes from the start that his/her life is at risk every time he uses it.
    And maybe the life of passengers too.
    Regular inspections are required during construction to make sure his work is acceptable.

    Super Rio was done right.
    Don't cut corners and settle for "good enough" and it will be safe and strong.
  9. JAFO

    JAFO displaced Jeep guy.....

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    Location:
    Charleston, SC
    I'm wrapping up a very extensive build of my truck that's followed this same mindset. This is why what I expected to take 3 months has taken just over a year... my plan had to be changed when I realized my brakes were going to be sorely lacking.

    Sent from my MB886 using Xparent Green Tapatalk 2
  10. jdrocks

    jdrocks Gravel Runner

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    4,613
    that's a standard right hand thread, please, no heat.

    1 1/16 impact socket, not 27mm, lock the sprocket off against the swingarm with an old 3/8 socket in the correct length (or steel pipe nipple), breaker bar with a cheater and pop it loose...and it will pop when it lets go.

    no thread locker from the factory, it takes in excess of 300# of torque to loosen.

    do NOT have the transmission in gear.
  11. Krasniewski

    Krasniewski I don't ride much.

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    Awesome - thanks for the info! :clap I'll give her a whirl in a bit.


    The sprocket is smaller than stock, that's the reason I thought it may be loctiteededed - previous owner had played with it.
  12. Krasniewski

    Krasniewski I don't ride much.

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    OK, thanks to JD for the tip - new sprocket is in!

    Big difference - pretty much what I was looking for.

    Bike is now very rideable at all legal speeds. Last week I took the laptop out to the bike and hooked the Power Commander up. I leaned out the very top end so that now it revs through *almost* the entire rev range smoothly, leaned out a little bit of the mid range, but mostly just smoothed out the transitions. End result is buttery smoothidity.

    Went out to Julian today with a couple of guys and hit up a couple hundred of some back country roads. EDIT: New seat was realllly nice to have. =)
    [​IMG]

    A couple hundred miles and I have three more things to add to the list: make mirrors match (one broke, used some random other one that was laying around - the stock ones blow donkey chunks), beef up tail light mounting, and shield the air filter from all the junk the rear wheel kicks up.

    Also, picked up a new project bike yesterday.
  13. Hotmamaandme

    Hotmamaandme Wishing I was riding RTW

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    Great! Get that new project bike all done up so I can buy the KLRE from you! Thanks:D
  14. Krasniewski

    Krasniewski I don't ride much.

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    Ok, hit up the taillight mount today.

    Old - thin, flimsy stock plastic cut up to fit. My bad for doing it in a hurry the first time.
    [​IMG]


    New, angle-aluminum for stability:
    [​IMG]


    The hard bag mounts flex a bit too, maybe those will be redesigned someday.


    I was going to redo the whole mount for license plate too, so I bought some alu, then changed my mind when I got home and used what I already had. BUT - I did get sick of not having the right tools for even basic stuff. In light of so much garage work recently, and my next bike being another project instead of a nice, new power machine, I felt entitled to a drill press and a band saw. Home Depot has really gone down the shitter in terms of tools here - they didn't even have a metal cutting band for the only size band saw they sell due to switching suppliers. Whatever, they give me a 10% discount, so I'll deal with it and go back later or pick up the right blade elsewhere. Point is - I'm stoked.
    :rilla


    [​IMG]

    Put it together and hooked it up, and it's certainly not top quality, but I think they'll do just fine. :norton


    I still need to figure out a way to protect the air filter. I need a rear hugger or a sheet of plastic or alu - I could have picked that up today... I need to start carrying a note pad or at least using a shopping list. :deal

    EDIT: I really need to build or buy a work bench.
  15. Krasniewski

    Krasniewski I don't ride much.

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    Add to the 'to do' list - make a new rear brake lever and bleed the rear brake. It's OK but feeling a bit weak. Also, hook up the horn. Two little things I keep forgetting about.

    Just writing it down here so I remember...
  16. Outwardbound

    Outwardbound Been here awhile

    Joined:
    Jan 17, 2005
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    709
    Location:
    Strongsville, OH
    Hey Kras...

    Are you in base housing at NASNI ? I was there a long time ago and the pix from your garage looked like a place I lived before.

    How many traps ? I retired w 700 in the A6.
  17. Krasniewski

    Krasniewski I don't ride much.

    Joined:
    Feb 5, 2008
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    LA - Lower Alabama

    Heyo - not on base - just a rental out in town. :norton


    Less than 80 traps in my books - just startin' out and the traps don't come fast in the COD being day only and multipiloted.
    700 ain't too shabby though! :eek1 It's certainly something to aim for. :freaky

    Back off leave today - I'm hoping to work on the new tank a bit as well. Also, the Ricor shock came in, but it's labeled as needing two washers for model year up to 2007 - so I'll have to call tomorrow and see if she needs to be sent back or if I just skip the washers for 08+... hopefully the latter. EDIT: Shock is good to go - just wiithout the washers.

    On an unrelated note - I got two pairs of gloves in while I was away on some vacay! That makes me happy - got a great deal on some almost new SP3's and bought some new Cortech dirt gloves for the heat. Both will replace the same models that have been used and abused to utter ruin. The SP3's lasted for a LONG time - those were goat skin IIRC, these don't seem as sturdy, but the price was right. =)
  18. Krasniewski

    Krasniewski I don't ride much.

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    Ok, got the horn hooked up and a new fuse in, but the horn sucks. Not sure where I got it, but I need a new one. this thing sounds like it's covered in a wet sock... like a bus's brakes... like a sick goose. It's horrible. :puke1

    I had one KLR mirror and one Ducati Monster mirror before. The other Monster mirror was reverse treaded, so I cut off the threads and got to commission my tig for her first legit use. Simple stuff, just weld on threads from a bolt with standard twist.

    [​IMG]


    Got my new tank tig'd up as well. 95% of the job was cake, then the last little bit is always a kick in the nuts, especially since I'm not so good with the welder. Anyway, holds gas, looks a bit better than my other botch job. It's not as good as would have liked, but them's the brakes.

    Shock is up next for install. I also found the factory plastic bash guard - I might hack that up for some air filter protection. I like the size and plastic type - I'm thinking cut to size, punch some holes, and zip tie to the sub-frame and call it a day.

    I also want to sweeten up the fuel map a little bit...
  19. Krasniewski

    Krasniewski I don't ride much.

    Joined:
    Feb 5, 2008
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    Location:
    LA - Lower Alabama
    [​IMG]

    Put the new shock in + little guard for the air cleaner =

    [​IMG]


    Travesty of a tank: See and compare to pic above to see how much tank I cut off.
    [​IMG]

    After some thought, I decided that my filler rod was far too thick. A pro could probably hack it, but it's more than my simple mind can handle. Actually, I knew it right away, but what are you going to do, stop and go the store? No. You just fuck away the project over your obstinance. Lesson learned, buy thinner rod and feed faster. The real tragedy of it all is that I got sunburn, and I think it's from welding. If you think welding in short sleeves is dumb, you should see my heel since I was also welding in flip-flops.

    The real awesome mod today was wiping the windscreen clean.

    To add to the list - my grips are loose. I usually use friction tape and gasoline to set them in place. Now would be a good time to order some heated grips or elements to go under the grips.

    And finally - excuse the picture if it's wonky - I can't figure out how to keep it upright.

    Edited for no reason.
  20. Krasniewski

    Krasniewski I don't ride much.

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    Out of town for a bit for some school.

    Got bored and ordered some steel braided brake lines. That will give me something to look forward to in regards to the bike. :norton