Starting a new thread now that I have the KLR650 (last thread, was asking for advice on whether I should get the bike)
Today removed the fairings, seat and tank and went in search of more frame damage and the electrical gremlin that I discovered after unloading the bike at home.
Well, I'm glad I got right into the bike because I needed to sooner or later, and very happy to see the condition is better than I had worried. Some top end noise I noticed at the end of the test ride, but found today that it was 3/4 qt. short of oil. Just barely visible in sight glass. For 2.5 qt total, that seems like a whole lot.
When I got the bike home I had meant to go on a victory lap to the beach, but instead upon pressing the starter button, something shorted out with a loud *snap* and the bike lost all power -- no headlight, turn signals, silent relay etc.. Then, an hour later, it had power again, and started fine.
After doing some preliminary looking today, I'm a bit puzzled about the electrical problem -- the sound of an arc directly coincided with all power being lost, but no fuse blew, and power is back now. An arc would be (+) to (-) shorting, but aside from this, I feel like it should be a faulty ground. Maybe multiple problems masquerading as one? The starter sensors are buttoned up now (removed and shunted) so that's not it. Checked the chassis ground, Black/yellow cable coming from harness and grounded on right side of steering head, seems fine. I remember the arc coming from the left side of the bike, apparently under the tank. Hm...
One odd thing I noticed is the Black/yellow bullet connector spliced right next to the battery (-) terminal was disconnected. A Black/yellow also disconnected in the plug box behind the headlight.
Since doing these things, the bike has not arced or lost power, but I'm not convinced. Never had the aha! moment. Haven't been able to replicate the fault state either. Will do some resistance testing, check the ignition switch, and continue the search, replacing connectors as I go.
Anyway, happy to have all the plastic off, deciding what color to paint it -- black or white? Cleaning things up and familiarizing myself with every component. It's been nice having TWO bikes to compare between; parts bike is much less mucked with -- good and bad -- and I've noticed a few electrical components absent on the runner I will have to identify.
Now, although it's probably too early, not having spent some time on the engine, I'm trying to decide whether it's worth swapping the 11lk motor in. It sure is purdy. Did a bit of looking into just titling the parts bike frame in VT, and building it up rather than the current bike, but looks like it's one year too young to be registered without a title in good ol' VT. I guess things got stricter there. Seems silly sitting in front of this pile of bikes that the VIN on the frame is what "makes" a bike legally, but I can swap motors no problem. Weird.
Anyway, that one dent in the frame I was worreid about is pretty much it for frame damage, unless it's skewed, which I have yet to measure, and upon closer inspection and cleaning, am please to say has very little rust.
The Honda met in the garage is a friend's I'm working on, waiting for a new carb.