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.