2008 KLR650 Lightening Project

[SamM]

My '08 KLR is a great bike. It was purchased new in 2007 from Romney Cycles for $4895 OTD. I set it up to do some light touring with Pelican cases, SW-Motech racks and crashbars, a new muffler, 19/17" Excel wheels, etc... However, I really wanted something for all types of riding. In the future, my rides will be geared more towards true dualsport, off-road/dirtroad/gravelroad exploring. The stock KLR front forks worried me, as I think they are a bit too flexy for that type of riding. Mine had started to badly rust even after I removed them periodically for cleaning. They also weighed quite a bit more than I thought was necessary. I added the EM fork brace but it didn't change the handling enough and it never stopped the rust. What I wanted was a lighter KLR.

My KLR project was born from this. Here are a few pictures. I appreciate all comments, even the negative. When you post... "you could have had a KTM for what you spent". I'll just post back... "already have one!" My 950 isn't a great bike. It's expensive to purchase, maintain and repair. I was also tired of walking and being rescued. The KLR was much cheaper than the Adventure and these mods didn't cost me much. I sold all the stock parts from the KLR that you don't see to buy the replacement parts. I have about $450 out of pocket costs on the USD conversion. The bike is also getting new dual FLUIDYNE radiators and later on new Excel off-road wheels. Haven't weighed it yet but I'm hoping for 300 to 340lbs. Weight is being removed daily and there is still much to do. I've also went on a diet myself and have lost 15lbs so far. SlimFast and salads! I'm trying to set a good example.

The new USD forks and frontend parts are from a 2008 Kawasaki KX450F. They are brand new and cost me $600 off ebay. My stock KLR forks were sold for $500. The bike uses one custom part and everything else is stock from Kawasaki, IMS, FLUIDYNE, Trail Tech or Moose Racing.

I'm sure I'll forget a lot but here's a list of the additions that I have made or have already purchased and are ready to bolt-on this weekend:

Happy Trail black skidplate
'07 KLR seat cover
Cycleracks.com rear rack
Moose Racing shifter
Moose Racing footpegs
Moose Racing airfilter
Moose Racing magnetic drain plug
Moose Racing Flex CR-high bend handlebars
Universal 1-1/8" handlebar clamp
Moose Racing aluminum throttle tube and control cam
Moose Racing handguards and air deflectors
Moose Racing KX450F front wheel spacers
Moose Racing KX450F braided front brakeline
Trail Tech Vector computer
'07 IMS fuel tank
Black '08 bodywork (used to be Red)
Kawasaki 'Monster Energy' front fender & fork guards
'07 KX450F wheel assembly
Nissin KX450F caliper and 250mm KX rotor
Gel grips
Westco Gel Battery
Shock Racing LED turnsignals
White Horse flashing LED taillight

I still need a Trail Tech X2 headlight and a muffler.

SamM






 

[Mac]

Very nice set up so far. I like the new front suspension. And I'll be the new front brake is somewhat better as well.

[ZED]

I think your goal of 300+ lbs is reasonable.  I was considering stripping one down for motarding before I got the WRX.  I see you took off all that heavy crap at the rear.  That's a huge amount of the dispensable weight right there.

I like the idea of a different fork.  Thanks for posting which ones you used.  That should be easy to come by.  I put cartridge emulators in my KLR.  It helps, but it's certainly not the end-all be-all.  What triples are you using?  I'm sure they don't just slide into the KLR ones.

Now, if someone can just work out how to give the damn thing a 6-speed...

Looks good. 

P.S.  I won't say you're wasting your time.  After all, think of a KLR as a blank canvas  and some starter material to create what you want.  And, as you've seen, a KLR is a required item in the stable so that it can be used as a rescue bike for the others. 

[SamM]

Thanks Mac and ZED. There is still much to do on the bike. The weekend has been a bust for me, got sick yesterday. Either an undercooked hamburger or some questionable pasta salad? Might get something done today if I feel better.

Anyway, I also want to mention that I have a 17" Excel 4.25" wheel leftover from the last version of this bike. I'm thinking about having Woody's Wheel Works superlace me a matching 19" Excel for the new USD frontend. I already have a spare KX450F wheel ready to send them. Tourance tires in 140/17 and 110/19 sizes could be run to make the bike more streetworthy for on-pavement trips with my non-dualsport riding buddies. I'll go tubeless with those.  

The front KX brake hasn't been tested out yet but I believe it will closely match the stock KLR front brake. For now, I still plan to use the stock KLR Nissin mastercylinder but a future addition may be a new KX450F Nissin mastercylinder. The stock KLR rotor was 280mm but the KX rotor is only 250mm. The KX Nissin caliper is much better than the stock KLR caliper though, so it should be a more powerful braking system overall. Galfer makes an oversize 270mm front wave rotor for the KX. It comes with a caliper relocating bracket and new pads. If I send them my rear KLR rotor they say they'll make a new matching wave rotor for the new '08 KLR and add it to their product line. Apparently, they don't make them yet.  

ZED,
Yes, the KLR is a great rescue bike. VERY dependable and easy to work on. I really loved the KTM 950, one of the reasons it's still sitting in my shop. A cracked exhaust pipe, a bad rear caliper and a few other troublesome issues has kept me off it for quite sometime. The caliper was rebuilt under warranty but it's never been right. Replacement is my only option. I've been thinking about a new project using the 950 as the basis for a sidecar rig. I've always wanted one. However, the LC8 engine would have to go to make room for something more economical and dependable. When the KLR is finished I may add another project to the list.

SamM

 

[leeo45]

Very nice updates.  The old KLR's are as reliable as a rock and I think you've attacked the worst weakness in the front forks.   I'm not a fast rider but I didn't like the disconnected feeling of the front end both times I've ridden a KLR.   Great work.

[sagerat]

Dang, that's one baaaaad looking KLR.  

[Max Wedge]

Looks good!
I bet that rear disc set-up weighs next to nothing!

[chimera]

Mad Max would be proud.  

[ZED]

Very nice updates.  The old KLR's are as reliable as a rock and I think you've attacked the worst weakness in the front forks.   I'm not a fast rider but I didn't like the disconnected feeling of the front end both times I've ridden a KLR.   Great work.

Yeah, the forks are a bit of a disappointment.  A fork brace, springs, oil, and cartridge emulators makes a world of difference.  They still can't compare with big cartridge forks though.


So, Sam.  How did you adapt the forks?  Enquiring minds want to know.

[SamM]

Posted by: Max Wedge
Looks good!
I bet that rear disc set-up weighs next to nothing!

Well, the title does state Lightening Project! Seriously, the rear rotor bolts stripped when I was trying to removing them from my other set of wheels. Haven't fired up the welder to remove them yet. That loose end should be tied up this week.

The KX450F USD fork conversion on my KLR650 involves one custom part. The factory KX450F steering stem was machined to accept the stock KLR650 steering head bearings. The KX stem is a little short, so I also cut the top of the KLR steering head tube down about 1/4". I still need to work out the top bearing seal but that's an easy issue to resolve. I just haven't had the time to source a seal yet. The bearings are now preloaded with the top clamp instead of a nut under the top clamp. My KTM 950 is setup exactly the same way. It shouldn't be a problem. The steering head nut will be drilled and tapped for a retention set screw and I'll watch it very closely.  

SamM

[SamM]

Here are a few more pictures.

SamM

[mtrider16]

Thats quite a project, and your doing well.  

Didn't you like the looks of an XR650R?

David

[ZED]

OK, that explains it.  Thanks.

[SamM]

Thats quite a project, and your doing well.  

Didn't you like the looks of an XR650R?

David

Thanks David!
I'm not a big Honda fan, so I never really thought about getting the XR650R. I already had the KLR and liked it a lot. I just wanted a lighter bike. After adding an electric starter and other equipment, that the KLR has stock, the XR650R is just a big heavy dirtbike. The XR also has an aluminum frame and subframe. The subframe is troublesome. It's a proven Baja winner but I prefer a steel frame and subframe. Less to worry about. This thing will HAUL a load. My KTM 950 Adv is just too heavy to take off-road, it's a better streetbike. Making the KLR lighter seemed like a better choice and like I said, I already had it. The bike is also paid for. This project is a win, win situation for me.

Posted by: ZED
OK, that explains it. Thanks.

ZED,
Machining the KX450F stem cost me around $75. The top clamp bearing from the KLR fit the KX stem perfectly. I had to have the bearing surfaced moved down in order for it to work. The threads were removed in that area. The bottom bearing surface was machined to fit the KLR bearing. There was nothing else to do except remove the extra metal from the KLR frame. It's a very straight forward swap.

SamM

[RideWV]

Sam,

I've watched this bike go through two transformations now!  Both impressive.

When you are ready for a shakedown ride, join rdoug and myself for some local dirt. (of course I have to acquire another dirt rig before that but that should be soon enough).

James

[Max Wedge]

 

[verboten1]

Man, I see you everywhere on the web....lol

[Max Wedge]

Man, I see you everywhere on the web....lol

Who?

[verboten1]

Who?

sam

[VAbikeguy]

I would love to know more about rust developing on the forks.  I'm about to take possession of a new 2009 KLR650 and haven't heard of this problem before.

[verboten1]

I am on multiple KLR650 sites, and attend many gatherings a year and have never heard of rusty forks

[RideDualSport.com]

A most excellent job you are doing on the KLR. It is a mighty fine bike!

[SamM]

The rust developed under the stock fork clamps. It was tough to removed but came off the fork chrome fairly easy. If I would have left it there, it would have eaten into the forks and been impossible to remove. Sadly, I didn't take pictures and I no longer have the stock parts. My bad but they did rust!

I will admit that I had let the bike sit in the rain a few days without the cover on it. Never again!  

Not much to report on the project right now. I'm getting a few things done. I've taken the year off from streetriding, so I'm not really in a hurry to finish it. I just bought another 2008 KLR650 and I've been working on it also. Splitting my time between two projects automatically cuts any progress that I may make in half. Be patient!

Here's a couple of pictures of the USD fork project. As you can see it's taken a bit of a turn.

SamM

[SamM]

Yes, it's REALLY light now!

Sam

[ZED]

Yes, it's REALLY light now!

Sam

You beat me to it.  

Those forks look great.  I think a sub 300lb KLR650 with that level of suspension would be awesome.    
Unfortunately I will no longer risk my radiator off-road and any decent armoring adds huge weight.  My KLR weighs in at 420lbs with a stock tank full of fuel.

[R Doug]

Wow, what an epic overhaul on the classic KLR.  Thanks for the updates.

Say... you don't have any left over parts from your 950 do you?  

[SWriverstone]

Sam, you do realize that you could make some money by perfecting this overhaul...then marketing either detailed instructions (you could make it a Word doc or PDF file that people could buy and download) with or without actual parts!   I'd consider doing it if a kit made it a total no-brainer with the only requirement being labor.  

Then again, I'm okay with my heavy-as-lead KLR because I don't do any serious dirt riding on it (just fairly well-graded unpaved roads). And I like being able to throw mine off a cliff, then have it run over by truck and still be unscathed due to all the heavy-as-lead armoring all over it.  

Scott

[brittus]

Looks like a neat project bike.

I have had my '88 KLR for so long geologists use it to study plate tetonics- she has almost 165,000 miles so far.

I've thought of lightening the bike in different ways (7 other KLRs have gone through my hands from cherry bikes to a $300 black spraypaint special that had already done Baja three times before I got it) and have come to the conclusion that without getting rid of important components (battery, starter motor comes to mind) that most weight loss would be incidental, like plastics and the few relays one could do without.

The USD forks weight more than stock ones, so there's an addition not a subtraction. It would be neat to know what your actual weight loss is. You can do one-wheel-at-a-time w/bathroom scales, and as long as you use the same scales the before & after would be relevant. I have found that material recycling businesses as well as gravel yards/quarries also have truck scales that you can sneak onto- the scales are maintained and weigh down to the pound with amazing accuracy.

Aluminum subframes (and mainframes) bend in spills, and the weight diff isn't that much. I have KLR600 and the subframes aren't much lighter, 3-5 pounds maximum as a guess. I second the opinion that survivability is most important for a KLR- I looped a 65mph wheelie and rode the bike home (thanks Renthal for your awesome handlebars) and would sure hate to get stranded due to a mod that saved a few pounds.

On the positive side, hell yes let's hear it for another great project bike, one that gives the owner a bike he or she loves and has spent time on!

I am from Charleston WV and though I have lived away for many years, everytime I go home with my KLR I love how she goes around the mountains! I'll bet you have some great dualsport areas up there in Motown.

[ZED]

Wow!  Pretty scathing for a guy with only two posts.

Welcome to the forum by the way.

The KLR is pretty much a blank canvas.  Folks do an awful lot of different things with them.  Some of the KLR projects I've contemplated are:
- transplant a smooth 500-650cc two cylinder engine.
- turn it into a light weight 300lb (wet) motard.    Not likely with the parts that I've weighed on it.
- do an upside down fork conversion.  My do that if I find the right parts donor.

Beauty is in the eye of the beholder.

[SamM]

Well, I guess I should update this thread. Sometimes you have to go backwards in order to make some headway. My plan for the KLR has been changed, yet again! My intent with this project was to limit my streetriding (health problems) and use the bike for more off-road riding (which is ok for me to do). I've tried to stop streetriding but it didn't workout for me. I must ride motorcycles that's what I do. My doctors have told me to stop riding but I just can't do it. I'm happier on a bike, at least my wife thinks so! After 9 months of not riding, I'm getting back into it. Because of all this, the original stock parts from my first 2008 KLR650 have been used to build a new motorcycle. The new motorcycle took me about one week to put together. I've gone back to an almost completely stock 2008 KLR650. The main reason for going back to stock is that RICOR Shocks has just released a new Interia Active Suspension System for the KLR650. These parts are getting rave reviews and I have decided that I must have them for my green KLR650. In order to install the Ricor Intimidators on my bike, I needed stock forks. I also thought that I would miss the stock KLR fairing and windscreen during roadtrips, so it's all back to stock for me! Here's a picture of the new KLR. The only additions are a new 2009 KLR650 wiring harness, a few Moose Racing parts and a cycleracks.com rear rack. The stock KLR rear rack and turnsignals will eventually go back on the bike.



This brought up an interesting situation. What to do with the original KLR frame and the USD fork conversion. Actually, I had another plan for the frame brewing already. This time the bike has undergone a VERY radical lightening process. All that I have left from the original motorcycle is the frame. Here is a picture of the bike as it sits today.



The bottom frame tubes have been removed and the downtube has been shortened. Twin 1" downtubes will soon be added. A new engine cradle and the twin downtubes will be required for the new engine. I will be installing a 456cc air-cooled single into this frame. Many will ask, why? There is no reason other than, because I just want to. Actually, I think the new engine will be a good match for this motorcycle. The bike will have mostly 2007 parts. From the fuel tank to the rear swingarm. A new 2008 subframe has already been purchased and the bike will have rear bodywork from a 2008 KLR. I already have all of that. The engine hasn't arrived yet. I'll be on a trip out of the country starting Friday, so nothing will be started until I get back. The new engine may require me to switch the final drive over to the rightside of the motorcyle. Not sure on that yet. I've gone back to a steel fuel tank because I don't think I need the extra range of the IMS tank. The used but like new 2007 fuel tank cost me $45.







Overall, I think brittus is probably right. However, I do think you can get a KLR down to the 300 to 325lb range. After you replace all the steel parts with aluminum you can drop a few pounds. But as brittus points out, the problem is that once you get down so far there just isn't much further to go. Removing required equipment is about all that's left. Of course, removing the stock engine, radiator, wiring, gauges and basically everything else will get you somewhere but the bike has to be redesigned. Not everyone wants to go there. I love to tinker and fiddle with things, so my stuff never does quite get finished.

That about does it for the KLR lightening project. I suppose I could update when the new engine is installed. If you guys are still interested?

SamM

[RideWV]

I'll be interested in your opinion of the Ricor Intiminators.  They make them for the 41mm forks on a Kawasaki Concours and I bet those will fit the 41mm forks on my ZR-7S, and I'm seriously considering them.

You going to bring that KLR out to ride with us sometime?

James

 

[ZED]

I finally remembered to dig up some parts weights from my KLR.  These may be interesting for those following this thread.

- Fully assembled with Happy Trail nerf bars, engine gaurd, skid plate and about empty of fuel 174.5lb front and 207.5lbs rear = 382 lbs.

- Without subframe, battery, airbox, nerf bars, muffler, or mid-pipe,  or seat
162.5 fr + 159 r = 321.5lbs

- mid-pipe and muffler = 9.5lbs
- Battery and airbox = 15lbs
- Battery = 11lbs
- Subframe without battery and airbox = 20lbs.

So, based on that, as much as I would like one, I don't see ever having a KLR in the 300-320 wet range.  The subframe just doesn't account for enough weight.

However, awesome project Sam.  Thanks for the update.  Really looking forward to hearing how the engine swap goes and what you think of the stock fork mods.  Both are of extreme interest to me.

[SamM]

I'll be interested in your opinion of the Ricor Intiminators. They make them for the 41mm forks on a Kawasaki Concours and I bet those will fit the 41mm forks on my ZR-7S, and I'm seriously considering them.

You going to bring that KLR out to ride with us sometime?

James

Hey James,
What bike are you riding now? Didn't I see you the other day? Sure, I'd love to go for a ride. Leaving for the Galapogos Islands tomorrow evening, so it will have to wait for a little while. I rode the KLR to work lastnight. Just made it home. Still need to get a set of crashbars for it before any serious off-roading. I bent the last SW-Motech bars I had on it. Going for the H-Ts this time. PM me here or email me at:
swmatteo@yahoo.com

I just ordered the complete RICOR IAS system for the KLR. It will probably take awhile as I think they are pretty backed up for now. I wanted to be sure to get the lower price while it was still available.

Let me know when you want to ride!

ZED,
I probably should have weighed that bike before changing it all around again. I'm looking forward to getting the new engine and doing some fab work on the bike. There's still quite a lot to get for it. Should be interesting. If you need a hint about the engine check my signature!

Off to bed. Gotta work tonight!

SamM

[brittus]

Nice follow up Sam- I had an EX500 motor all set to go into one of my frames years ago- but I couldn't bring myself to do the fab work for the swingarm-pivot-through-the motor at the time. Of course I got the idea from a British bike mag ad for the KLE500, which is just that.

Zed, he did ask for negative comments in his thread opener remember?

Considering what new purpose-build dirtbikes weigh, the 300lb KLR650 is a high bar to clear.

Kawasaki already came close to this mythical bike- the KLR600- which is quite a bit more diminuitive than the 650. The 650 motor won't drop straight into the frame (multiple engine mounts off just that little bit each) but one could always pump the 600 motor up a little bit if they needed to.

-------

After years of working at a dealership and having my own small shop I arrived at the theory that a bike/rider ratio of 3:1 is about right for a "street" bike- go above that and the bikes' mass makes it harder for the rider to control in "sticky" situations... at the same time any weight reduction below that gives every bit more control. Jump from a street-legal sportbike and onto the same bike stripped for track-only use and it's night-and-day.

Personally I have always thought about making my own smaller fuel tank. My '88s original tank began to leak at the rear mount and it hangs from my shop ceiling. I could cut it apart and use the base but I am no sheetmetal worker and offroading needs knee-steering input- it would be hard for me to make a smooth tank upper or one that looks good.

If only IMS would make one...

b.

[SamM]

brittus,
Myself, I have no problems cutting motorcycles apart. Been doing it for a long time. I have a KTM 950 Adventure that I'm trying to figure out what to do with. Oh well! Someday! The EX500 or better yet the new Versys engine would be a great swap into an '08 KLR. That would make a great Adventure bike.

I believe the new engine that I'm swapping into my KLR should be very interesting in this bike. Can wait to get my hands on it. I'm hoping to get 100+mpg out of it. The bike may be light enough to take off-road a little. We'll see! I'm commited to it at this point. I'll post a picture below of what I hope to achieve.

Honestly, I didn't see anything in your post that was really negative. Truthful yes, and I'm fine with that! Even the negative doesn't bother me. The USD forks do weigh quite a bit more than I originally though. When you factor in the weight of the new KX450F wheel versus the KLR650 wheel and all the other parts caliper, brakeline, fender, gauges, fairing, there is a reduction, not much but a little. Right now my frame weighs 27lbs. Just weighed it. That's a pretty good starting point but it's not finished, so that will go up a good bit.

The picture below shows what I'd like to end up with. My diesel powered motorcycle will have an automatic transmission and no foot controls whatsoever. The rear brake will be actuated by a handlebar mounted mastercylinder mounted on the leftside of the handlebars. This m/c is from Rekluse and is for a KX450F. It will match up perfectly with the stock KX450F mastercylinder and KX frontend that is on the bike. The stock brakelever and all of the stock KLR rear brakelever parts/mounts will be removed from the bike. I also want to add that this project is mostly a learning exercise. My real plan is to convert my 2005 KTM 950 Adventure into a diesel or perhaps a diesel/electric powered motorcycle using a more powerful engine.  

SamM

[KenH]

I don't think diesel/electric will be much advantage on the street, but if your riding requires gobs of low-speed torque, and you can work around the weight issues, diesel/electric will deliver. Yes, I know 99.999% of train engines are diesel/electric these days, but those really are concerned with a lack of traction from not being heavy enough. I don't think the torque advantage of diesel/electric would really be much of an advantage, anyway, because most any 500cc 2-valve single can rip the knobs off the biggest knobbies available. On the other hand, diesel/electric would be simple to ride--no trans or clutch, regeneration to provide "engine" braking if sufficient battery capacity is available. It sounds like an interesting project.

[SamM]

The only real reason to look at a motorcycle powered by diesel, bio-diesel or diesel/electric is as an alternative fuel source. That's the only reason I am interested in it. I have a real problem spending my money at the gas pumps knowing that it's all going overseas to Saudia Arabia. Recently, I've looked further into the diesel/electric option it and at this time it's not as viable as I would have hoped. I did find a new hub motor that would work but the motor would require a 12 to 15kW generator to power it up. Packaging the components could be a problem in a motorcycle. It could be doable in a 950 but I'm content to keep working on my diesel/CVT KLR for now. My engine will be here shortly and I'd be getting more into it this Winter.

The diesel powered Track T800CDi is built on the KTM 950 platform. Very interesting but not at $24,500.

SamM

[KenH]

Diesel comes from the same Arabian oil barrels as gasoline. Bio-diesels are not as easy to find as first glance would indicate. Too many people with home fuel systems running their ancient BMWs and Mercedes on grease these days. In some areas sources expect payment when they used to pay to have their waste grease hauled away. I have several friends who do the grease thing, and a couple have destroyed engines. Some farm co-ops have virgin bio-diesel so you could check those out as a source. Pretty good federal subsidies keep the prices down. It takes a lot of attention to detail to convert cooking grease to diesel fuel.