Dumb question but .... - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 31 Old 03-02-2019, 06:10 PM Thread Starter
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I’m removing some of the pounds of worthless weight on my bike (besides me) and have been looking at the header heat shield and the shield behind the rear brake reservoir. Do they really do anything? Has anyone removed them and damaged their rear brake reservoir from heat? I know they don’t weigh much but cumulatively these things add up.

Last edited by EricZ; 03-02-2019 at 06:31 PM.
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post #2 of 31 Old 03-02-2019, 06:30 PM Thread Starter
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I figure people run an FMF powerbomb with that big expansion chamber and no heat shield so maybe I don’t need it. Please don’t lecture me about the negligible weight loss. Manufacturers spend $$$ trying to engineer a 20 pound weight loss off their revised models. I figure maybe I can do it by unbolting pointless or overweight parts and with strategic replacement with lighter (exhaust). Besides I want to compensate for the skid plate, better hand guards and rear box. Thanks.

Last edited by EricZ; 03-02-2019 at 06:37 PM.
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post #3 of 31 Old 03-02-2019, 07:38 PM
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I would retain the brake fluid reservoir heat shield. A riding buddy of mine has overheated his rear brake system (2009 model) twice on rides that I have been with him. We are still a little uncertain as to exactly how & why. I wouldn't risk that little item.

If your leg never touches the exposed header, you will probably never miss that heat shield. But if your rain suit touches an exposed header pipe you will have a wet spot!

Look at your passenger footrest & brackets, Rear inner fender, Lithium battery, Leo Vince X3 pipe never needs repacking because it is mechanically baffled instead of glass-packed.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #4 of 31 Old 03-02-2019, 07:41 PM
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Ride the rough stuff on the bottom half of the fuel tank! Add gas on the other side of the mountain. 6lbs x 3 gallon = 18+ lbs up high.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 31 Old 03-03-2019, 12:30 PM
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I've lightenened my KLR's for my "offroad centric" use and Paul's hit what I call the "low hanging fruit" of KLR weight loss. In addition I've removed some other extraneous bits; snorkle and cover, upper chain guard, sidestand safety switch and mechanism, factory tool kit (I carry lighter tools in my fanny pack). I also use an IMS 6.6 tank which isn't lighter than the stocker BUT negates the need for 12-14lb crash bars. My alloy bars and alloy pegs (knight designs) are also lighter and I use a hybrid alloy/steel sprocket from Supersprox (not much weight savings for the $$).

I wouldn't remove the reservoir sheild - it weighs almost nothing......and since nobody else has bothered, you'll be in uncharted territory. Do you want to be the one to confirm you need it? The header heat shield is a bit heavier, though not alot; if you want to remove it, go ahead - lots of KLR's are missing them.....if you want to retain some heat protection use header wrap instead.

If you want to lose 20 more lbs, sell your Gen2 and get a Gen1! ;-) j/k

2 cents,
Dave
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post #6 of 31 Old 03-03-2019, 03:15 PM Thread Starter
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My main concern with removing the header heat shield was damaging the rear brake light switch. Apparently that doesn’t happen. I’m not too worried about the heat on my leg as I very rarely ever ride in shorts and if I do it’s only for very short distances. I also don’t use rain gear (yet) so no worries about melting it. Thanks

Last edited by EricZ; 03-03-2019 at 03:23 PM.
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post #7 of 31 Old 03-03-2019, 03:45 PM
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I have kept my header shield as I find it keeps my flip-flops from melting.

Tom [email protected]

“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

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post #8 of 31 Old 03-03-2019, 06:08 PM Thread Starter
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Hahaha. Never fear, the shorts are limited to occasionally putting up to my buddies house a mile up the road. I know shit happens but if I can’t reasonably manage a mile on a lightly traveled country road I need to quit.

Part of my weight loss plan is the integrated Tusk handguard LED turn signals, direct attach rear fender LED signals and eliminate the stock front and rear with associated brackets. I was planning on using the Tusk LED relay box and removing the stock flasher. Thoughts?

Last edited by EricZ; 03-03-2019 at 06:12 PM.
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post #9 of 31 Old 03-03-2019, 07:04 PM
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EricZ, your KLR650 weighs in the neighborhood of 432 pounds wet, if I'm not mistaken . . . including 6 or so gallons (6.3 lbs/gallon) of fuel. How much weight do you think you can lose, what percentage? Also, what effects/benefits do you expect from your weight-reduction program? An edge in motorcycle competitions?

Just askin'. Your bike, your choice in modifications. You are the ONLY one to be pleased. Best wishes in your, "Weight Watchers" program for your bike!

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #10 of 31 Old 03-03-2019, 07:43 PM Thread Starter
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I sense a lecture coming. I’m Just trimming the easy fat and adding some style to it on the relative cheap. It’s still gonna be a pig but if I add real handguards why not integrate front led turn signals and ditch those giant wings, fake hand guards and bar end weights. I saw some more appealing $20 mirrors, I like led turn signals and the rears stick out too far for a tip over anyway. I want a more stylish Lexx pipe that sounds a little better without being obnoxious and adds 2 or 3 hp. I’ve already ditched the snorkel, rear pegs and brackets, inner rear fender, cs guard, chain guard and a few other odds and ends. I’m going with a KTM mx front fender and will ditch some of the common extras and brackets I haven’t mentioned yet. I’ll add some braided lines and ditch the stupid rear brake line loop.

Yeah, stock it’s 432 pounds and 35 hp. What’s so wrong with trying to make it 412 pounds and 38 hp, with a little more style and response if I can do it for $500 or less? There are people who add 30 pounds with $5000 worth of chrome and crap on their Harley’s. I’m not obsessing about it. You can polish a turd, a little bit anyway...
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