DCM sidecar suspension mods - Kawasaki KLR 650 Forum
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post #1 of 8 Old 10-13-2016, 02:31 PM Thread Starter
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DCM sidecar suspension mods

New-to-me 2012 KLR 650...I'm installing a DCM cargo box sidecar on it...anyone do a sidecar one and what suspension mods did you do...or suggestions.

DCM has a progressive rear spring and I've found several front suspension sites.

I'm still wading through the previous sidecar posts.

Any relatively recent conversions and/or new mod information will be appreciated...

I also have a 2002 Moto Guzzi EV 1100 Cal special and a BMW R65 I built sidecars for in the past...body falling apart and I need "training wheels" to keep on motoring...

Thanks SIDEREAL.
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post #2 of 8 Old 10-13-2016, 02:53 PM
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See this post and maybe try reach out to Adventure Sidecar.

http://www.klrforum.com/341593-post6.html

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 8 Old 10-13-2016, 02:57 PM
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Actually just checking and notice he hasn;t been on here for quite some time. May respond to a PM though.

Also it's DMC sidecar not DCM. MAy help in your search.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #4 of 8 Old 10-13-2016, 11:40 PM Thread Starter
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Thanks klr4evr...yeah I know...stiff fingers, I didn't correct and I do that twist around all the time even when talking to Jay G. at DMC.
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post #5 of 8 Old 10-16-2016, 01:40 PM Thread Starter
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Hummmmm...not a lot of interest, understandably. I'm on dial-up and it takes forever just to log in...I have to drive 20 miles to get WI-FI...I live way the hell out in the boony's of Oregon...

Someone knowledgeable posted some good reply information just a few post below when I first logged in but I can't find it searching under "suspension, rear suspension, rear spring" etc...would someone please tell me WHO it was and WHERE it was posted...I just scanned it and thought I could find it again by searching the site.

I'm in the process of contacting Progressive, Cogent, and Touratech for information on their suspension products. According to one post the OEM rear shock itself sucks so just replacing the OEM spring with a heavier one doesn't seem to be cost effective. This machine has 10K easy mostly road and logging roads miles, I'm a broke down 250# fat body and the side car empty weighs close to 250# including mounts so I need something that will carry that weight PLUS what's in the box.

This conversion has been done several times including DMC's own very kool KLR650/Sputnik sidecar demo rig. I've emailed Jay at length for the last several months getting info and I've watched several YouTube vids but not a lot of specific suspension mods are forthcoming or I just haven't found the right URL.

Again...thanks for any directions or information.

SIDEREAL.
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post #6 of 8 Old 05-26-2017, 11:19 PM Thread Starter
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End of May and finally done...Winter caught me...Box and Bike under 4-6 feet of snow...other SH** happened so didn't get started putting things together until mid April...Sent rear shock off to be rebuild and heavier spring installed...installed progressive front springs...stripped off tank, seat, front plastic panels...had a few glitches in the DMC box installation, the main front strut mount was welded together wrong so it wouldn't clamp...had set of GIVI side protectors installed that required some "fixits", NOT DCM's problem but required some alterations to get the front strut installed...basically just took a couple weeks here and a couple weeks there which added up to a couple months of time "bumps".

Spent yesterday and today sorting steering...the DCM box NEEDS WEIGHT. I did a HI-chair and took a shot at an embankment just for kicks on one right hander. I have some 3/8" plate that will take care of that problem. The added weight requires a 15T sprocket to replace the 16T stock one...55 MPH at 3500 RPM is basically lugging the engine and with all the hills and curves and dirt roads around here I either had to run in 4th gear or down to 3rd to keep it humming.

While all this was going on I found a 1988 Honda GL1500 with a Hannigan sidecar for basically chump change I just COULDN'T pass up...52K on a 30 year old machine...not perfect, but only a few warts and OH so many niceties. Needed a new sidecar tire and will need the toe in re-adjusted...new car shock...doesn't need them but I will replace the fuel/air/oil filters and oil changed. Has a automobile rear tire and fork geometry adjusted for sidecar use and it steers like a dream.

Anyway, thanks again for the heads-up in the "stuff".

SIDEREAL
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post #7 of 8 Old 05-27-2017, 12:36 PM
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I recently put a Sputnik side car on my KLR from DMC Sidecar. I used Jay's attachment hardware and subframe made specifically for the KLR and had him upgrade the rear spring. I also purchased his disc brake set up for the side car which was a good move. Jay is great to work with and his products are well engineered and well built. The KLR is a good tug from a sidecar as long as they are will matched and Jay would be good source for information in getting the right match. This is my 3rd sidecar, the first being a Ural. I consider the KLR and Sputnik to be a better expenditure of money that the Ural. I also one time had a Suzuki Bandit 1200 with a Texas sidecar. It was a great ride. Unfortunately it got wiped out when a cager decided to occupy the same space I was driving on.
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post #8 of 8 Old 05-28-2017, 12:42 PM Thread Starter
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Yeah...Jay's good people, he tried to sell me on the Sputnik but I wanted more storage and that red color was just WRONG.

I thought he had sent me the wrong struts from looking at the build pics which were the older ones with forks on the ends. That's what I used for all my connectors...hiz'n/herz so to speak and like many other strut setups from other sidecar mounting hardware...that's what looking too hard can do to you...you miss the simpler stuff.

I've built a couple of other sidecars or rather built one for a Beemer then modified it to fit my Guzzi so now I have 3 hacks to pick from...each one fitting a different purpose and style of riding.

I looked at the URALS hard a few years back and almost bought a used one (2000?) with the drive wheel but wasn't too impressed with the motor or some of the comments I read so I passed...the people who had them that I talked to seemed happy for the most part at least the newer ones from 2010 and later.

Anyway, 75 lbs of lead shot works great at keeping the hack where it belongs while I sort the plate and get a piece of carpet to cover it.

My problem has always been I like to build things and once they are finished I get bored with them and start on another project...doesn't matter what the projects are...cars, motorcycles, guns, boats...I usually build them then sell'um and start something new and completely different, but I think I will hang onto my hacks because I need "training wheels" to keep on motorcycling. I've been on "two wheels" almost 70 years and living' would be sh** without it.

Enjoy your toys.

Last edited by SIDEREAL; 05-28-2017 at 12:50 PM.
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