Shortening my Kickstand (side stand) - 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 16 Old 05-12-2020, 11:55 PM Thread Starter
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Shortening my Kickstand (side stand)

My plan is to do this, but i am curious to hear from those that have done it, how much did you shorten yours? Any pics would be cool also. Thanks!
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post #2 of 16 Old 05-13-2020, 01:04 AM
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Funny you should ask, I just shortened one today for someone.

BUT.... I'm going to be right up front and say that I used to be an automotive mechanic and have all my own tools, and now that I'm retired, built up my own shop in my garage.
This is ONE WAY to do this, and there are many other ways to accomplish the same thing.

You will need some basic tools, good saw, a welder (or access to one), and grinder.




I took a magnetic angle block for welding and used it to make four straight lines to keep the the angles right. Use a marker or sharpie for the top one at both ends of the scribe.
This will be explained later.

Then I used a punch on one of the lines to mark OUTSIDE the cut area to measure the total cut length.

Then I cut about 7/8" out of the lower portion of the tube. Try to find some pipe or rod the same as the inside diameter to splice it together. I have a metal lathe, so I turned down a piece of solid rod I had laying around.



After cutting the 7/8" out, I used a bench grinder to straighten the edges out, then wire wheeled them. I then drilled three holes in each piece near the edge. Cleaned the inside of the tubes with a sandpaper drum on a pneumatic grinder. That sleeve I made was pretty close to press fit, and should fit into place by hand.
I also drilled out the rod to lighten it up a bit.



Placed the sleeve in place into the lower portion, and welded it into place with rosette welds.



Now here is where the four lines around the shaft you made come into play.
Slide the pieces together and line up your scribe lines being careful to get the color marks lined up.
This will make the angle of the foot pad pretty close to where it was.

Weld up the other three holes, finish off with some light grinding or sanding, and your ready for some paint.



After everything was done, it wound up to be shortened by 15/16".

Hope this helps.
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Confidence is the feeling you have before you fully understand the situation."

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post #3 of 16 Old 05-13-2020, 08:35 AM
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I cut the foot off mine and shortened the tube 1" welded the foot back on.
A hacksaw cut a little bit of grinding and its doing its job again.
I removed the switch at the same time.

Terry

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post #4 of 16 Old 05-13-2020, 08:48 AM Thread Starter
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Very helpful thank you!
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post #5 of 16 Old 05-13-2020, 09:41 AM Thread Starter
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I believe I am gong to have it done this way. I think it is the strongest way to do it.

Quote:
Originally Posted by terry_g View Post
I cut the foot off mine and shortened the tube 1" welded the foot back on.
A hacksaw cut a little bit of grinding and its doing its job again.
I removed the switch at the same time.

Terry

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post #6 of 16 Old 05-13-2020, 09:44 AM
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I did the same as shown (cut 1", grind, smooth and re-welded it, rattle can paint). Have loved it ever since. So much better, highly recommend.

Sammy

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post #7 of 16 Old 05-13-2020, 09:53 AM
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aside from the methods;

- 1) make sure your sag is set properly first

- 2) to test the amount you want to cut, drive up onto boards of the thickness you are thinking of cutting and see what it looks/feels like. adjust the thickness of the boards/spacers as necessary.


Dave
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post #8 of 16 Old 05-13-2020, 10:25 AM Thread Starter
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make sure your sag is set properly first? I have seen before, What does that mean?
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post #9 of 16 Old 05-13-2020, 11:32 AM
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There may be something about setting the sag if you try a search by the same name.
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post #10 of 16 Old 05-13-2020, 11:42 AM Thread Starter
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I looked it up. I have never carried a load on this thing. I believe if I take off 3/4 I will still be fine for any adjustments I may have yo make.
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