KLRE 650 - Ninja powered KLR.

[Kraz]

Ok, so thanks to RepsolRider and his Super Rio on ADV, which is the basis for this build.

http://www.advrider.com/forums/showthread.php?t=640772&highlight=kle650

KLRE is a KLR650 with a Ninja or Versys 650 parallel twin motor in it.

Apologies in advance - I had LOTS of pictures, most of which got deleted by accident.    Basically the finished product (well, still have some details to touch up) is all the pictures I have, but just wanted to post her up anyway.

















Anyway, this is an amateur build at best, so excuse the shitty welds and setup.  I've only ridden the bike around the block so far, but so far, seems like plenty of power and similar weight to what it was in stock form.

Also posted on ADV, so apologies to those who monitor both forums.

[veefer800canuck]

What prompted the "interesting" exhaust?

Usually a slipon on stock headpipes for a thumper performs just fine.

[veefer800canuck]

Oh, nevermind, I get it now. I thought the twin headpipes were one for each exhaust valve, as Honda has done on some thumpers in the past. Sorry. Missed that.

[Kraz]

Ha!  My bad - guess I shoulda mentioned what this even was in the first place.

Original post edited to reflect what she is.

The point is to a have a smoother, more powerful, modern, fuel injected motor with 6 gears... I already had a KLR, and didn't want to blow a wad of money on a Tiger 800 etc. (though I would love one).

[Yankee Dog]

how much does it weigh.  more or less than a stock KLR??

[Kraz]

They say the motor is ~5lbs heavier than the single... I didn't weigh her, but it feels the same to me before and after.  Weight wasn't a concern for me really since the KLR is kind of a tank to begin with.  I dropped the skidplate and crash bars for now, so it actually may be really close to the same.

[DogBoy]

I like the original KLRE650 (at the start of the ADV thread) much better. As long as you're doing major mods, why not upgrade the suspension. The engine is not the weakest point of the KLR.

[scottzilla]

I admire the attempt for sure but the KLR chassis is pretty weak.  Throwing more HP and Torque may not be the answer.  I think this is why Kawi never built a 6sp, 2cyl KLR all these years.  It would have to be a completey different bike, you know?  

[veefer800canuck]

I like the original KLRE650 (at the start of the ADV thread) much better. As long as you're doing major mods, why not upgrade the suspension. The engine is not the weakest point of the KLR.

I think he was doing this on a budget, hence the lack of suspension bling.

But a decent aftermarket shock and some upgraded springs and fork internals would certainly help.

[Kraz]

Ok, well the front has progressive springs and new fluid, as well as a fork brace.  I actually love the way the front end feels now... it's as upgraded as it needs to be, but thanks for asking.  I really don't see the need to swap over to USD forks.

Rear shock?  Maybe someday.  It's an easy job and I don't need to do it right now.  This whole thing took a lot of time, but very little money.  I'm not really throwing money at bling, as has been mentioned, though it would be nice.  I'd love to take the time and money to build one like that other guy, but again, just a fun project to play around with, not a pro project, not a pro budget, no pro tools, and definitely no pro skills.  

I had a 685cc kit, and still found the motor grossly lacking.  Power was low, it's a 5 speed, and not smooth at all, lugs at low RPM so she was picky about the gears.  I guess if I have to explain why a new motor would be a good thing... well... nevermind.

EDIT: Further updates on ADV - wrong crowd for this kind of stuff I guess.
http://www.advrider.com/forums/showthread.php?t=710918

[stavro]

nice work man turned out well.  

[Nodaclu]

Love the idea and the execution!  

How difficult was it to mount up the new motor?

[919]

It sounds to me like you took a great all around motorcycle that could do everything, and made it better at everything, without breaking the bank.  

Have you found any drawbacks?

[Kraz]

Thanks for the responses...

Love the idea and the execution!  

How difficult was it to mount up the new motor?

The frame had to be altered a bit - but if you're comfortable with a welder it's relatively simple.  The hardest part is the lack of room for an airbox... I'm still playing around with that.  There are more pics of the build in the ADV thread I linked a few posts up.  All in all - she's pretty good as she sits, but if I figure out something permanent for the airbox, then I'll probably get power commander and a custom dyno map to sweeten the pot.

It sounds to me like you took a great all around motorcycle that could do everything, and made it better at everything, without breaking the bank.   Thumbsup

Have you found any drawbacks?

You hit the nail on the head with the "without breaking the bank" deal.  '08 KLR with goodies ran 3 grand or so - by selling the motor and buying a wrecked Ninja 650, I'm only in the hole a few hundred bucks.  Next best deal in my book would be to off-road-ize a Wee-Strom, or buy a Tiger 800 or 800GS, so I'm VERY happy with what I have for the money!

The only drawback is the fact that it's relatively unknown and unproven, but I'm not taking it to South America, so that doesn't bother me much.  I put it through some good abuse the first time out on washboard and dry river crossings, so I'm pretty confident in the strength of the frame.  The only other thing is the fact that I basically can't sell it - and I usually don't keep bikes more than a year or two, so I may be "stuck" with this rig for a while.    So far I don't really want to - but if the time comes where I want to go with something else, I may as well cut it down and sell it for scrap as I'm more than somewhat concerned about the legal ramifications of selling something like this in America, let along California.  

Overall, the bike is sooooo much better all around.  Next to the K12S, it's still a slouch, but it's night and day compared to even the 685cc single in terms of power, smoothness, and overall rideability.    Plus, I feel pretty good about might first really BIG project turning out well.  

[919]

The only drawback is the fact that it's relatively unknown and unproven, but I'm not taking it to South America, so that doesn't bother me much.  I put it through some good abuse the first time out on washboard and dry river crossings, so I'm pretty confident in the strength of the frame.  The only other thing is the fact that I basically can't sell it - and I usually don't keep bikes more than a year or two, so I may be "stuck" with this rig for a while.    So far I don't really want to - but if the time comes where I want to go with something else, I may as well cut it down and sell it for scrap as I'm more than somewhat concerned about the legal ramifications of selling something like this in America, let along California.  

You couldn't sell it "As is, custom"?  I feel like that would take care of liability, no?  Otherwise you could sell it on STn or ADV, if someone from these sites buys it you have to believe that they knew what they were getting.

Sent from pocket computer

[Kraz]

You couldn't sell it "As is, custom"?  I feel like that would take care of liability, no?  Otherwise you could sell it on STn or ADV, if someone from these sites buys it you have to believe that they knew what they were getting.

I don't know - you're probably right - but the whole thing just scares me.  Sounds logical to me, but courts don't seem to go far on logic anymore.

Maybe I'm just scared of what it'd actually sell for now.  

[Kraz]

Well, bike is dead in the water... won't start for nothin'.  Can't figure it out.  

What's scrap steel sell for these days?  

[Nodaclu]

Sorry to hear that!!

Most of the time, the first place I look is fueling, but in the case of a transplant like yours, I'd probably start with electrical.

[Andrew]

Well, bike is dead in the water... won't start for nothin'.  Can't figure it out.  

What's scrap steel sell for these days?  

How much??    and no I am not the litigious type

[Kraz]

Thanks for the advice, the more i play with it, the more I think you're right...

I took off the intake, and you can see the fuel spray if you crack the throttle a bit, and you can see the valves moving, but the fuel doesn't really seem to get sucked completely down the intake, and what does, doesn't ignite.  Which is realllly odd, as the plugs fire very often.  Once in a while you can get it to pop a little, but that ends up being flames in the intake...    I'm quite certain the timing is off - so maybe a new ECU will fix the problem?  I hate to throw money at it, but it's that or take apart all the wire bundles looking for a short.

I'm guessing the ECU went bad on its own, or I jacked it up with my last bit of welding (even though I always have the negative terminal disconnected, and it was running b/f it died, and this is probably the 10th time I've successfully welded on this bike, though admittedly, I used a different ground point this time), or some water (or metal dust from grinding) got into a connector and ruined something electrical, or the timing is being thrown off by a sensor/magnet that isn't doing so hot - but I doubt the last two.

A buddy brought over a timing gun, but it didn't work, probably b/c I have the coil sticks and not plug wires.  

 How much??  Bigsmile  and no I am not the litigious type

Why, you got an offer?    I'm outta here for a bit in December, so I'll probably get rid of at least one bike before I go... probably this one for cheap if I can't get it to run.    I really need to get this running again so I can have something to commute on while I work on the K12S, which would be a much easier sell.    If an ECU doesn't fix this, I'm probably on the mtn bike as a commuter as I get the Bimmer back in to ship shape.