03 Military Style Fairing/Dash build - 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 18 Old 02-15-2016, 08:09 PM Thread Starter
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03 Military Style Fairing/Dash build

Here's a few shots of my fairing and Dash Build. This began as a Rally Fairing project several years ago, but got sidelined by life numerous times. I changed directions and stuck with what I know. Milspec equipment. Nothing fancy - get the job done.

First I did the Wheatwhacker mod to angle the windshield forward and open up the dash area. I have a Buell XB headlight installed too.



This is the new Dash, mounts to metal brackets behind the Wheatwhacker plates. I have a custom Quadlock & Rammount for my iphone on the left, and the right is my Rage windows CE GPS. Switches and breakers are marine grade & water resistant. Right is a dual USB jack, left is a standard 12v jack. One switch is for the Dash, the second is for the LED lights.



Here's a shot of the back:


Then I got a JNS light mount and a set of budget LED lights off Amazon and did a test install.



The lights are really bright, but there are some issues using them with the light bar. Nothing unusual there - I tend to modify everything to fit my projects.



The JNS bar is comes with 6mm holes for smaller lights. My lights showed up with 8mm brackets and hardware. If you look at the first picture, the bolt heads were too tall and rubbing on the fairing. The wiring that came with the light is heavily jacketed and stiff, making for a difficult install behind the fairing. I decided this would be a good time to pick up a new tool - the UniBit. I had already drilled out the light mount holes to use the 8mm hardware, now I added 2 holes for the wire management.



I took my grinder and made thin bolts.



Then reassembled - nice and clean now:


I have some issues to resolve with the dash. I did not use heavy enough metal, and the GPS vibrates more than I'd like. Looks like I need better side brackets and a thicker dash.

I'm also going to modify the Aux Light switch wiring so that I can turn them on directly, or I can have them follow the High beam. So I guess this is still a prototype - one more version needed to get it strong enough.

Hoping to get some pictures of the bike this week. Can't get a nice pic in my crowded garage.

Ethan
HighSpeedHiker

Last edited by HSHiker650; 02-15-2016 at 08:13 PM.
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post #2 of 18 Old 02-15-2016, 08:33 PM
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That is a "very tidy" install HSH. Well done.
Well 'almost' done, as I re-read the last bit.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 18 Old 02-15-2016, 08:40 PM
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That's pretty cool and way to think outside the box. It will be one of a kind KLR
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post #4 of 18 Old 02-15-2016, 09:55 PM Thread Starter
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Thanks, this is fun stuff for me. I'm pushing to finish the bike refresh before the weather clears. I think I'm going to install more bracing on the inside and run this for the season. I needed to get some rivets into the look antway. Still have a fork rebuild, new tires and wheel bearings to complete. Then the final touch - I'm narrowing down the color scheme and vinyl wrap selection. I need to order supplies tomorrow, so the choice will be made over my morning coffee.
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post #5 of 18 Old 02-15-2016, 10:22 PM
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Here is a link to a camo vinyl wrap supplier if you're interested.
Pattern Guide: Find the Best Camouflage Pattern for your needs!
Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #6 of 18 Old 02-16-2016, 07:45 AM Thread Starter
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Nice, I've looked at a lot of camo. That Morning Wood is hilarious.

I'm going in a bit different direction, tribute to the surface fleet and what a KLR would look like if it was carried by the SEALS. Yeah, I know about the Marine KLR, which was carried on ships. Instead, I'm thinking what if the Navy & CG had them set up for security operations. Sure would have been nice to throw a bike over the fantail when we pulled into some questionable places and had to manage a large perimeter. Maybe something in battleship grey.
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post #7 of 18 Old 02-16-2016, 08:09 AM
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Nice job!
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post #8 of 18 Old 02-16-2016, 10:47 AM Thread Starter
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Thanks, forgot to mention I also am running the Trailtech Vapor digital dash, mounted on an outdoor electrical box. The box makes for a nice junction box and raised the Display just above the ignition switch. Keeps my keyring off the display.

The Trailtech dash has my indicator lights, same as the stock KLR lights, Neutral, High Beam and Turn signal. The 4th (lower left) position is a Gammatronics programmable LED voltage monitor (from Ebay). The programmable part refers to the ability to set it up for the desired voltage and display cycle. I like it, simple Red,Yellow,Green display. lets me know if I'm having a charging issue or when it's time to put the bike on the trickle charger.

Very much looking forward to getting out of the garage soon.
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post #9 of 18 Old 02-16-2016, 02:18 PM
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HSHiker650,
The Morning Wood is my favorite as well. I'll be interested to see pics when you have it done!
Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #10 of 18 Old 02-16-2016, 05:07 PM
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Quote:
Originally Posted by HSHiker650 View Post
Maybe something in battleship grey...
Yes. Very good. We will then know we don't have to salute it.

...but then really, you should be considering something like this...

http://metrogiant.com/metrorestyling...alNavyCamo.jpg
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