2008 KLR650 Lightening Project

[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.

[SamM]

Ok, sorry that I've been gone for awhile but I have decided to get back into this project.

Last year, I didn't ride much due to health issues but I'm ready to get back into riding. The doctors have switched my meds around and I should be good to go. The new '08 KLR that I put together last August is now getting the USD KX450F forks due to a new conversion steering stem from Emig Racing. Here are the updated pictures of my bike and the new stem in my KX clamps. It pretty much looks just as it did before. I won't be using the stock '08 KLR side panels this time around. I have a new JNS skidplate for it. The bike also has new Galfer 'Wave' rotors and will sport a complete KX450F frontend. From the mastercylinder to the axle. There will be new pictures in a week or so. I just bought the new'07 KLR radiator and the last parts that I need to finish it up. It should be up and running in a couple of weeks. You may notice it has a new seat. It's a new custom +2 Ralley Slealth seat from Renazco. The last picture shows the 2007 KLR650 rear linkage. This was a direct swap and should allow the RICOR IAS shock to have close to 9.5" of travel out back. Trail Tech will be sending my new X2 dualsport headlight, a Vapor Stealth kit and the rest of my parts sometime this week.  

For those that are interested, I am still doing the KLR diesel engine conversion on my other frame. That bike has been put on hold for awhile. The CVT manufacturer went belly up. Still much to aquire for that one. Best left for another day.

SamM

[SamM]

Another small update. I'm still waiting on some last minute parts that I need to get the bike finished. Here are the latest pictures of it. The KLR still needs some wiring and the radiator installed.Waiting on radiator hoses and a fan switch. New KTM Military folding mirrors are on it and the Renazco seat is great.

SamM