KLR 650 Modifications

Discussion in 'Thumpers' started by VascoMerlin, Aug 24, 2006.

  1. C.John

    C.John Epic Ride Report Wannabe

    Joined:
    Oct 14, 2011
    Oddometer:
    195
    Location:
    Far east Iowa
    I maxed out the preload to lessen the amount of spring compression I'll need to remove the spring. Compress it some, release the preload and already have some initial wiggle room to remove the spring. Or at least that's the theory based off of watching YouTube videos.
    BigFatAl likes this.
  2. C.John

    C.John Epic Ride Report Wannabe

    Joined:
    Oct 14, 2011
    Oddometer:
    195
    Location:
    Far east Iowa
    Got the 450lb spring, I used to run stock spring at #3 preload
  3. black 8

    black 8 coddiwompling motographer

    Joined:
    Dec 11, 2016
    Oddometer:
    3,064
    Location:
    33.202738 -117.384040
    Yes they do make it look easy in the videos.

    Hint: If the hooks on the spring compressors are too big they will dig into the shock body and black plastic cover. I tried to install my 9kg Eibach but the hobby shop I went to didn't have the right spring compressors so I used their tech shop and was charged $9.00 for the labor to use their hydraulic spring compressor.
    C.John likes this.
  4. C.John

    C.John Epic Ride Report Wannabe

    Joined:
    Oct 14, 2011
    Oddometer:
    195
    Location:
    Far east Iowa
    Finished up this morning. Wrapped the coils in gorilla tape to protect the paint, then used 4 hose clamps to compress the spring. Probably not the safest but I still have all my fingers and eyesight so I'll call it good.
    Initial ride impression, wth no preload...I should have done this 5 years ago. Rides nice.
    IMG_20170424_111558717_HDR.jpg IMG_20170424_114921407_HDR.jpg
    SteelCityADV, BigFatAl and TreyJK like this.
  5. BigFatAl

    BigFatAl Long timer

    Joined:
    Aug 24, 2016
    Oddometer:
    1,419
    I use s set of these from RMATV.
    [​IMG]


    Sent from my iPhone using Tapatalk
  6. Hvymax

    Hvymax Been here awhile

    Joined:
    Sep 22, 2016
    Oddometer:
    449
    Location:
    La Plata MD
    I did a 600 in lb for mine.
    C.John likes this.
  7. smokediver3

    smokediver3 Adventurer

    Joined:
    Feb 16, 2012
    Oddometer:
    70
    Location:
    West "by God" Virginia
    So, I was wondering why I couldn't see SH** at night when riding my KLR, but after removing the fairing and having the headlight fall apart it was no longer a mystery. KIMG0081.jpg
    Standby for the fix.......
    griffo1962 likes this.
  8. julien

    julien Adventurer

    Joined:
    Aug 29, 2012
    Oddometer:
    36
    Location:
    Montreal (Canada)
    Aouch ! :/

    If you need a light in a good condition, I've one removed from a 99 KLR. (I can ship it, I'm from Montreal)
    thechief86 likes this.
  9. smokediver3

    smokediver3 Adventurer

    Joined:
    Feb 16, 2012
    Oddometer:
    70
    Location:
    West "by God" Virginia
    Thanks for the offer, but I've already done the deed & made an upgrade!
  10. smokediver3

    smokediver3 Adventurer

    Joined:
    Feb 16, 2012
    Oddometer:
    70
    Location:
    West "by God" Virginia
    I managed to search & scrounge around & saw a few posts about LED headlights. Well, due to the condition of my headlight reflector, just a regular bulb was not gonna cut it! After a few wonderfully wasted hours, I found my replacement on flea-bay.

    Attached Files:

    C.John and julien like this.
  11. julien

    julien Adventurer

    Joined:
    Aug 29, 2012
    Oddometer:
    36
    Location:
    Montreal (Canada)
    Nice LED headklight Smokediver3 ! :beer

    While I'm in the area, I will share with you my modifs.
    Here is my KLR 650 Gen1 "Rally" :D

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    The job is not 100% percent terminated.
    I'm still waiting for blinker and high beam dash indicator, my diy trip is still on development and I will upgrade the shock, but I had to reallocate the budget, so, no milestone planned yet.
    And in the future, I want to make a paint job (certainly kawa green and purple), some decals for the tank and a new seat.
  12. smokediver3

    smokediver3 Adventurer

    Joined:
    Feb 16, 2012
    Oddometer:
    70
    Location:
    West "by God" Virginia
    Then it was off to practice my very inadequate fabrication skills since this did not turn out to be a drop in proposition.

    Attached Files:

  13. julien

    julien Adventurer

    Joined:
    Aug 29, 2012
    Oddometer:
    36
    Location:
    Montreal (Canada)
    Nice build
  14. smokediver3

    smokediver3 Adventurer

    Joined:
    Feb 16, 2012
    Oddometer:
    70
    Location:
    West "by God" Virginia
    But once it was fabbed up, it was a pretty easy install. Then putting the fairing back on, it fit just like it had to. I have plenty of light now. Even in the daytime I can see the light reflecting back from road signs. Night time riding has taken on a whole new "light"! (Insert rim shot & canned laughter here!)

    Attached Files:

  15. smokediver3

    smokediver3 Adventurer

    Joined:
    Feb 16, 2012
    Oddometer:
    70
    Location:
    West "by God" Virginia
    Not a bad rig you got going on there yourself! I like the use of the fairing to hide the stuff you've added.
    julien likes this.
  16. rystjohn

    rystjohn KLR slut

    Joined:
    Mar 22, 2013
    Oddometer:
    113
    Location:
    Eugene OR
    That's awesome. Mines starting to rust ever so slightly. Sent you a PM - would love to know the make/model of the LED light you used and where ya got it.

    Thanks for sharing your upgrade!

    Sent from my XT1585 using Tapatalk
    thechief86 likes this.
  17. MaverickR

    MaverickR Adventurer

    Joined:
    Mar 21, 2017
    Oddometer:
    27
    Location:
    Muncie, IN
    I got my 08 klr back in November, that had 26k miles on the clock. When I got it, all it had done was the doo and the carb. I am new to KLR's and ADV riding, but not new to motorcycles. Since I have gotten it, I have done:
    progressive fork springs
    EM fork brace
    lowered and modified the stock fender
    klr dash w/ taller windscreen
    bar risers
    tusk handguards
    skid plate
    pannier racks and panniers
    rural king box that I screwed onto the factory rack
    12v outlet
    walmart seat cover
    walmart tank bag
    cramp buster
    ims shifter
    ebay foot pegs
    PCV valve

    still want:
    crash bars and K60's would be nice.
    I'm not entirely sure if I need a rear spring, but I'll probably get one eventually.

    If anybody has any questions about the mods that I have done and wonder how well they work feel free to message me, and Ill tell you what I think.
  18. ColdBoulder

    ColdBoulder Adventurer

    Joined:
    Nov 26, 2014
    Oddometer:
    75
    Location:
    Utah
    Im looking at replacing the headlight and all that plastic on my 2008. I will be going with a Trail Tech Vapor for the dash portion of it. As far as lighting I was taking a look at the Cyclops Rally, heard good things about it and its halgenic performance. Then I ask do I need such a thing, although I do like it, probably not. I have now been looking at the JW Speaker 8700 Evo 2. This would give me enough money to purchase a center stand. However, has anybody done this. It looks like one of the best 7" out there even maybe a little better then Truck Lite and the price for one is decent. But, what bucket would be a good bucket to put it in on the KLR? I just don't know what bucket would be good, and do I stuff all the wires in the back? Im new to this.
    This plasma money is burning a hole in my pocket...
  19. XDragRacer

    XDragRacer Long timer Supporter

    Joined:
    Mar 25, 2009
    Oddometer:
    5,033
    Just askin': What's your impression of the effect of the PCV valve mod?
  20. griffo1962

    griffo1962 Long timer

    Joined:
    Oct 24, 2006
    Oddometer:
    1,899
    Location:
    Carrara, Qld, Australia
    this +1