Has anyone posted up a "how-to" to swapping Gen 2 forks on to a Gen 1 frame? I've been puttering away on my latest project bike, have it pretty much together. I like to putter away in my spare time fixing up and overhauling KLRs, and this is number 6 or 7 I've done, and maybe the last. Prices for used KLR parts on eBay are really getting up there, and this will be 4 KLRs hanging around, and I've sold 3. Hard to part with 'em after building them up.
Current state of progress, mostly together and running. This one has the Wossner 2mm OS (678cc) HC piston, ported head, the standard airbox mods, and a Vance & Hines pipe. Sounds sweet. I had that top end on a different bottom end - the high compression adds snap!
One of the problems in swapping a Gen 2 front end, on to a Gen 1 frame, is that you no longer have a means of mounting the stock instrument cluster to the top triple. I installed a JNS LED headlight (NOT DOT compliant BTW), and made my own mount for a Trail Tech Vapor display:
I'll talk a bit more about the Trail Tech Vapor unit further along in the thread.
The steering stops are very different between Gen 1 & 2. I have a friend that's a master metal fabricator, is an amazing welder. I cut the Gen 2 stop out of a frame I scrapped, and had him weld it on (beautiful job):
The back fender mounting lugs, on the underside of the lower triple, contacted the Gen 1 stop prematurely, so I cut it off with an angle grinder cut-off disk:
The Gen 1 ignition cylinder isn't as tall as Gen 2, and sits down inside the casting, so I flushed it:
The Gen 2 rear suspension bolts right on. I did however use a Gen 1 Unilink, and E-M raising links to raise the ride height. On the front fork, I made 1 1/2" preload spacers to increase ride height and stiffen up the (very soft IMO) springs.
I used a Gen 2 subframe, because I like the nicer looking rear rack & fender. The upper subframe bolts are 10mm on Gen 2, 8mm on Gen 1s, so it's necessary to make some kind of hat bushing to reduce the hole in the subframe mount to 8mm dia. I used a pressed steel hat bushing I had on hand, on either side. I believe they are the bushings between the rack mount and fender plastic. I did the drill thru mod, used a long grade 10.9 or 12.9 bolt to pinch it all together - worked great. I robbed the rear tail light, license plate light, and turn signal connectors off an old Gen 2 wire harness, soldered 'em on to a new Gen 1 harness.
Any questions, or want more pics I'd be glad to help.