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Greetings from the north (winter is coming)

8K views 31 replies 11 participants last post by  GreatWhiteNorth 
#1 · (Edited)
Hi! I've been a member for a while, longtime lurker. Same on .net, but was fairly active on adv on that KLR thread (pre troll wars). Looks like a great bunch here, engaging in civilized, intelligent discussion (well moderated too). I've had, I think 7 KLRs, have become a bit of a parts hoarder, picking up KLR bits here and there. I retired from the RCAF after 35 years service, was an aircraft tech, a crewchief in the end. Interesting career, which took me all over hells half acre, but stressful. I enjoy riding and wrenching, overhauling and building up KLRs for a hobby, help local guys out with their bikes (pay it forward). Exploring in the country is what it's all about for me, and I've posted some ride reports up in adv. I'll share a few pics here. Looking forward to contributing, and getting to know folks in the KLR community :thumb:

This has been my current ride last two years, an '01 with 705 - it has the Britannia Composites fairing on it, Dirtracks crashbars & racks, H-T boxes:



This is a '96 692 "back-up/guest bike" I put together (it's sporting a Safari tank ATM):



The '08 Gen 2 that I put together, rode this a few years:



I've got the KLR sidecar rig to play with too. I've put quite a few miles on it, exploring the prairies. It's been thru several iterations, is currently 705:



I had this '94 692 for a couple of years... my buddy Reg out for a spring visit on the wife's Kawi Sherpa (both sold):



There's been a few more KLRs, a '96, and a KLR650C. We've had 3 Gold Wings, and I put a sidecar on the GL1500. Pics hosted by Photobucket... so if they don't display properly, you know why (buggers!).

Edit. Forgot the current '01 "hybrid" project bike, so that's 8 KLRs I've had!

https://www.klrforum.com/1987-2007-...ont-rear-suspension-gen-1-a-2.html#post693569
 
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#4 ·
Greetings and welcome from Alberta. Thankfully not as frozen as you. Former Goldwing owner myself. Gave it up for a Miata.

Unfortunate about your pictures. I’ve long given up on Photobucket. Maybe try and attach them to your post.

.
 
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#5 ·
Hi klr4evr. My buddy Reg, in that one pic, works at "The Fort", had the 1st KLR I built up. He's had a succession of other bikes since (they all become unloved :^)

Photobucket... they're playing silly bugger. I've been watching the threads, see they intentionally blur images, and then after a while they display normally. Dishonest IMO how they've done things, trying to ransom/extort you to subscribe, even tho you're within free hosting limits. Gotta find another free photo hosting service.

Suggestions?
 
#8 · (Edited)
lineman1234, that's a Dauntless Motors (DMC) Enduro sidecar. I don't know if that was their prototype, but it was their shoptruck used by the production manager. They put it up for sale, $4K USD with the '92 tug, and I had it shipped to the border and imported it. They sell the subframe and struts needed to mount it: Enduro

Steering gets heavy when you hang a sidecar on a motorcycle, and there's a tendency for the front end to oscillate, which can get out of control quickly if you take your hands off the handlebars. Quirky things to set up and operate. I managed to buy a DMC leading link front end cheap (they are $2K USD new!), still working on getting the sidecar rig back together after a major overhaul.

I registered with Flickr, will post up some test pics, see how that goes.







 
#9 · (Edited)
Imgur... let's try Imgur. The sidecar tug got overhauled, full frame up rebuild. Next I have to sand and repaint a good chunk of the sidecar frame:



Edit - it works! This is a '92, with that DMC subframe, leading link front end, and I hung a Gen 2 back end on it... engine is 705, on an '08 Gen 2 bottom end, ported Gen 1 head, OMG loud Staintune exhaust. You asked about gearing? 14T front/standard 43T rear. That's to help get moving from stopped (easier, effectively lower gearing). That gearing results in approx 4,700 rpm at 100 km/h (62 mph). Those aftermarket pistons eat that up, done right, no noticeable oil consumption (run that rpm all day).
 
#10 · (Edited)
Daryl, with flickr you choose the link associated with 'bbcode', paste it into your post and trim it back to the tags (so it doen'st post your flickr account name) like this:

Copy this:

[ url=https://flic.kr/p/2hWGMU2][ img]https://live.staticflickr.com/65535/49189450493_cda6ecf7fa_b.jpg[/url]IMG_20180830_1543143 by Dxxx Mxxxxl, on Flickr

paste it into your post and trim it to [ img]https://live.staticflickr.com/65535/49189450493_cda6ecf7fa_b.jpg[/img]


 
#12 ·
in flickr you can choose different sizes, too. Here is the original size, 4896 x 3672. The forum software will resize it to 1024, but if you right-click on the image and choose "Open image in new tab" it will open at full size. Can be handy.

 
#18 ·
I hit multiquote... probably not using that correctly (hmmm). One would sure hope they use a torque plate during boring & honing. I asked at the place I get my cylinders done (Millar Engines in Winkler, MB), and they said they use one. I'm thinking any machine shop familiar with doing Harley cylinders would do an OK job on a KLR cylinder.

I just started in to overhauling a Gen 1 head. I like to do head porting, have done a bunch. Think there'd be any interest in a "how-to"?

Daryl
 
#19 ·
yes, I've been told they use torque plates. I have a great relationship with my local machine shop (they did my 440-6 race motor) but I felt that it was best to get the guys that do the KLR cylinders every day to do them.....I've heard too many horror stories.

I miss Norm's input and interesting posts. I was surprised he went "cold turkey" but understand....

Yes, I think a porting "how to" would be of interest to some for sure.

Cheers,
Dave
 
#20 ·
Thought I'd add a couple of "fleet" pics. And yes, I know it's a little crazy having multiple KLRs. Maybe I'll sell one...



The current state of the fleet (plus one more out in the workshop) - they have it pretty good wintering inside. Our house had the garage converted into a living space... I am looking at converting it back!

 
#22 ·
Hi Belldriver! Nice to see you here (all the way from Germany :^)

Regarding the Tengai, Oh I know. The Tengai has been a twinkle in my eye for some time, and I almost bought a minty example. The guy agreed to sell it, twice actually, and then changed his mind, returned my money. I think he sold it to someone else for more. A couple of other examples came up in Alberta after that too, but I didn't jump.
 
#23 ·
GWN,
Do you have an actual OEM Service Manual for the KL650-C series bikes? Some of the information in it is almost worth it weight in 'lead'.

On FB it has recently been said that the fork oil volume & remaining air space is the same as the KL650-B series, can you confirm or dispute that?
 
#24 ·
I don't didn't have any manual or supplement for the KLR650C unfortunately. I seem to recall having found the info on-line tho? Although a Gen 1 KLR at it's roots, there were lots of little differences between it, and Gen 1 or 2s, much like the Tengai is quite different too.

I have, somewhere (misplaced it), the old Gen 1 factory manual with the Tengai on the cover!

Daryl
 
#25 · (Edited)
Thought I'd throw in a couple more pics...

On a trip with buddy Reg. His KLR is a 685 '96 I built up... and the sidecar rig. This is in Alberta, approaching Fort Pitt, along the North Saskatchewan River:



I took the sidecar rig out a bunch of times in winter - Brrr!



An earlier iteration... out with the wife in the Sandilands area of SE MB. This from on top of Bedson Ridge (near Woodridge) overlooking the prairies (highest spot in the SE):

 
#27 · (Edited)
Hi Retfird. Engine wise, bigger is better. 705 costs more, because of the aftermarket cylinder sleeve, making 692 better value. A JE 692 piston (what E-M sells), is lighter than the stock piston, so, like 685, smoother. IMO vibration is not an issue with aftermarket pistons - probably the 705 piston too is lighter than stock.

Sidecars really add drag and weight - a very good test of the clutch! Fuel economy wise, you can expect to pay (minimum) a 25% penalty dragging the sidecar around. With the stock engine, albeit a tired, soft on power oil burner of an engine, I could barely maintain 100 km/h. Throw in a headwind, I'd often have to shift down, struggling to maintain 80 km/h!

The fix? First I installed a 2mm oversize (678cc) high compression piston/ported head top end, with standard intake & exhaust mods - Yowsers! Top end increased to over 120 km/h, huge difference, easy to maintain highway speed. Unfortunately I blew the counterbalancer chain, toasted that bottom end, so upgraded to an '08 bottom end, and 705/ported head top end. Similar performance, but no need to run premium.

Edit - I should add, with the 705, I think I saw 128 km/h once for top end, GPS verified. Pretty scary to be honest, as with the Kenda K270 front knobby, feels very skittish at those speeds. Another quirky thing, accelerating away from a stop, when you give 'er the gas, front end gets light, and the sidecar drags you to the right - stopping, opposite happens, the weight & inertia from the sidecar pushes the front end left. Not for the faint of heart!

Daryl
 
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