Subframe Upgrade....and more. - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 7 Old 08-12-2014, 10:35 PM Thread Starter
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Subframe Upgrade....and more.

Not been on the list for awhile as I got laid off and relocated from Boulder, CO to Bend, OR (what a ride !!! ;-) Anyhoo I finally got my house and garage set up after a year here and started working on the KLR. New rebuild kit and Dynojet kit got the bike to carb like a kitten, best since I've had her. Then I noticed one of the subframe bolts was snapped off. Luckily (or unluckily) I had bought one of those 10mm bolt upgrades and hadn't had time to put it in, probably two years ago. Lawd, what a PIA !!! The snapped off bolt, I drilled into, and my Craftsman "easy out" snapped off; so now I have hardened steel in there :-( Used dremel tool grinding cones to get it out as none of the drill bits I had would drill through an easy out :-(. Long story short got the hole drilled from both sides, and then managed to bang the 10mm allen head bolt through to both sides of the subframe with a 2 pound sledge and wiggling on the aft side :-). Jeezus, I think this upgrade required the frame to be sideways and on a drill press to work; guess if you've done a lot it's easier, but with the snapped off one side it was a PAIN in the arse. Well anyway, we now have a subframe that shouldn't snap off anytime soon, and she starts without any choke (from parking in the garage),....love my new commuter bike as it's only 3 miles to work and I was paranoid about what it was doing to my Chevy pickup ;-)

Cheers,

John

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #2 of 7 Old 08-12-2014, 10:43 PM
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Welcome back, man. You've been missed.

Is it just me or is Bend, OR becoming a hotbed of KLR activity?

Tom

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post #3 of 7 Old 08-12-2014, 10:50 PM Thread Starter
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There are a LOT of KLRs up here, especially the old models. Bend is known as "Poverty with a view", seriously! I moved up here with a full boat move, but took a serious salary cut, but heh, it's all good :-) I live on the SE side of town where the locals live, on the west side of the river it's all "Californacators (I'm a recovering one ;-). Lots of dirt trails that aren't intense to ride, but you have to share with the ultra althete bicycle folks, all good :-). A guy at work as a KLR, same vintage of mine with studs in a "winter" set of tires !!! Given my stupidly happy short coummute to work I might set up a 2nd set of wheels, done my Aerostich full suit with armour and try to do the "winter" commute now that we are settled somewhat. Thanks for the welcome back, it's been awhile.

John

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #4 of 7 Old 08-12-2014, 11:22 PM
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There's a few folks from Bend here. I love the area. Been down there a couple times on the Goldwing.

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post #5 of 7 Old 08-12-2014, 11:23 PM Thread Starter
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That would be great as so far I've been riding a few poker runs on the FLH, but now dirt, trail friends as of yet !!!

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #6 of 7 Old 08-12-2014, 11:27 PM Thread Starter
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So given I did a butcher job on the 10mm bolt upgrade, has anybody enlarged the subframe and main frame much larger ??? As a winter project some day, if the mill is out of the mainframe, I could put it into my drill press and do a ~ >10mm bore and get it done "right". Yep, I'm and engineer hate to do stuff "good enough" ;-)

John

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #7 of 7 Old 08-12-2014, 11:36 PM
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Quote:
Originally Posted by RF_R_US View Post
There are a LOT of KLRs up here, especially the old models. Bend is known as "Poverty with a view", seriously! I moved up here with a full boat move, but took a serious salary cut, but heh, it's all good :-) I live on the SE side of town where the locals live, on the west side of the river it's all "Californacators (I'm a recovering one ;-). Lots of dirt trails that aren't intense to ride, but you have to share with the ultra althete bicycle folks, all good :-). A guy at work as a KLR, same vintage of mine with studs in a "winter" set of tires !!! Given my stupidly happy short coummute to work I might set up a 2nd set of wheels, done my Aerostich full suit with armour and try to do the "winter" commute now that we are settled somewhat. Thanks for the welcome back, it's been awhile.

John
Howdy,
I'm a long time Bend resident who just grabbed an '05 KLR to play with. I'm in Idaho for the summer and will be back in Bend late Sept. Let me know if ya wanna get in a ride. I used to work for the Forest Service there so have a good idea of some fun backcountry roads out in the desert.

2005 KLR 650- Red & Black
Wheeeeee!!!
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Skid Plate, Crash bars, Happy Trails fork brace, rear rack and aluminum cargo boxes, Africa switch, heated hand grips, rear master cylinder guard, taller wind screen, UNI air filter, SuperTrapp exhaust, HD shifter, off road pegs, HWY pegs, .22’ mod, 12.9 sub frame bolt upgrade, shortened clutch and hand brake levers, MSR handle bar bash bars, headlight guard, center stand, LED tail light and driving lights
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