2008 KLR650 Lightening Project

[ZED]

Spring has sprung, the grass has ris, wonder how the KLR is?

It's funny, I'd just dug up this thread to look at recently to re-read the conversation and here it is now active again.
We went to Moab on the little bikes and had a blast.  Then I got home and rode the KLR and thought what a heavy thing it was.  That got me thinking again about how much the KLR could be lightened.  

I'm very much looking forward to this next incarnation and its weight.  

By the way, did you think to compare the weight of the new forks to the stock KLR forks?
I expect the upside down forks are heavier, I wonder how much.  Next time I change the oil in my KLR and my WR250X I'll have to weigh them.

[SamM]

Hey ZED,
I still have a good bit left to finish. Mostly the wiring but I'm waiting on a few of the last parts to arrive. The tabs for the new radiator need to be welded onto the frame. I hope to get that done the middle of this week when I'm off work. I'm itching to get it finished so I can start riding. The wiring is the real hold up. This bike has way too much wiring. I wish someone made an aftermarket harness for these bikes. I need to find a place to stuff 2 feet of extra wiring. Not easy!

Never weighed the forks. I have another set of stock '08 forks, so I can do it. The inverts probably weigh more but when you consider that everything on the KLR is steel and the KX450F forks and components are all aluminum, they're bound to weigh less. Overall, there should be a savings with the complete KX frontend when compared to the KLR frontend. If I get the time I'll weigh them. Honestly, it doesn't matter to me. The KX forks are better! I recently replaced the KLR clutch lever assembly with on from a KX. There was a noticable difference in those parts. I'm also working out the rear Galfer brake rotor conversion. Galfer does not recommend their '07 wvae rotor for this application. I decided to use it anyway. A new mounting plate for the caliper will be fabbed by a local machineshop. Should be pretty straightforward and hopefully they can get it back to me very soon. It won't stop me from riding the bike, if I finish it as I have two separate sets of '08 brake parts. The correct Galfer brake pads are on the way. There is only a 10mm difference in the rootrs from the '07 to the '08. This can easily be fixed with the new conversion plate.

When I get more done I post the updates. I hope to have it finished in the next week or so.

SamM

[SamM]

Here are the latest pictures. I mostly just have wiring left to do now. The top picture shows the repositioned '08 wiring harness and ignition module. The new '07 radiator and fan are shown in the bottom picture. These parts were purchased off eBay. I was able to sell my '08 radiator for more than enough to buy all the '07 radiator parts that I needed. The ProCycle add-on ignition switch still needs to be adapted to the '08 stating circuit. Next on the list of things to do, is add the Vapor computer and LED turnsignals.

Overall, I think it has turned out very clean. Haven't weighed it yet. I'm actually afraid to. Not sure that I have dropped enough weight yet.

SamM

[ZED]

Another question on weight.

Have you weighed the stock steel tank and the IMS tank?
I wonder how much weight can be saved with that swap and I haven't found anyone that has actually weighed an IMS tank yet.

[SamM]

The IMS tank is much lighter than the stock steel tank. The 5 gallon IMS tank is on my list of possible weight reducing additions that I may buy to drop even more from my bike. I didn't weigh the tanks as I didn't really feel the need to weigh separate components. I'm looking at the overall package.

Remember the stock '08 KLR has heavy plastic tank shrouds.

SamM

[hobie1dog]

I recently found out about the new batteries that are using the a123 cells.  There are several companies making m/c batteries out of them.    A 4 cell battery provides 150 CCA and only weighs 11 ounces.  A 8 cell battery weighs 22 ounces and has 300 CCA   I'm not sure which Westco battery you have but the ones I looked up are in the 7 lb range.

You can Google up the a123 cell batteries and also go to Youtube where a guy starts his Integra 4 cylinder car motor on just 4 cells in -21 degree weather.

http://www.youtube.com/watch?v=qcvmvrmTMMk


Looks like a substantial weight savings for you.  Also you will find Googling up a123 batteries that the RC hobbies are using them all over the place with great results.  Most people are buying DeWalt 28 and 36 volt battery packs which have either 8 or 12 cells in them and taking the batteries apart and using the cells to make their own battery packs.  Plenty of info on how to do this too.

The companies that sell the M/C batteries are SpeedCell and E-BATT    

http://www.ebattonline.com/

[SamM]

hobies1dog,
Thanks for the link. I've actually seen those batteries before and I am seriously considering getting one for my KLR. Looks like I could drop 5 or 6 lbs quite easily.  

SamM

[hobie1dog]

hobies1dog,
Thanks for the link. I've actually seen those batteries before and I am seriously considering getting one for my KLR. Looks like I could drop 5 or 6 lbs quite easily.  

SamM

I just received my DeWalt 28 volt battery yesterday and now have to go and get the 10mm Torx security driver to take the battery apart to gain access to the a123 cells.  Gotta love all the government intervention to make sure that they protect us from ourselves.  

[SamM]

My bike is finished enough to ride and I'm back on the road with it. Recently, I had the bike weighed and it came in at 380 lbs. Now remember, this bike is an '08 and I have changed the fuel tank to an 7 gallon '07 IMS fuel tank. The tank actually holds more than 7 gals but for my weighing purposes I'm using 7 gals as my conservative number. That puts the fuel weight at 42.51 lbs and the bike at 337.5 lbs or 340 lbs give or take a few. Honestly, the bike feels like it weighs around 350 lbs. The difference in the posted fuel load numbers is probably the other few pounds that I feel. There are still a few ideas left to try on removing some more weight from it. I'll probably go with a 5 gal IMS tank and the bike still has the stock muffler and exhaust. My new exhaust includes an FMF header, Hindle midpipe, Kientech mounting flange and a 3.8 lb Titanium muffler from a GSXR1000. Just waiting on the midpipe to arrive to bolt it on.

A Rekluse auto-clutch, Excel 21/18" wheels, Neutech TUbliss wheel sealing system and a few other mods are in the works for later on.

SamM