What did you do to your KLR today? (2018) - Page 2 - Kawasaki KLR 650 Forum
KLR & Other Motorcycle Related Discussion Grab a seat and discuss whatever you like about the KLR or other related topics. Within reason.

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post #11 of 135 Old 01-07-2018, 09:42 PM
2nd Gear
 
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Join Date: Aug 2017
Location: Kincardine, ON, Canada
Posts: 168
Quote:
Originally Posted by Bluehighways View Post
Looks good. The disc to help prevent the shift Lever from putting a hole in the engine cover if/when the bike takes a nap on its left side, seems an excellent idea.

I can't claim credit for that.

I had contacted a manufacturer/retailer that makes an extended lever about modifying one to fit me. Several emails went back and forth, but it ended with "he'd have to give it some thought".

So I moved on, made a drawing and gave it to welder to it. The washer I had put on the back replicates what the manufacturer does with their design.
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post #12 of 135 Old 01-10-2018, 12:55 PM
1st Gear
 
Join Date: Mar 2015
Location: Colorado mountains
Posts: 76
I pulled my forks and drained, cleaned, and inspected them, and drilled and tapped the lowers for drain plugs. Now that I have them apart, I'm considering adding the Cogent DDC package, too. Never been entirely pleased with the way the suspension worked, so we'll see. I'm in no hurry; still months of possible snow ahead, though this has been an extraordinarily mild winter (so far). On to pulling the triple tree and cleaning and re-greasing those bearings.

Conrad Long
'08 KLR 650
'96 R1100RT
'94 R1100RS
'75 XS650B
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post #13 of 135 Old 01-10-2018, 05:44 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,687
Liftrat,
I recently measured 397mm / 15 & 5/8th inch from top of Gen2 leg to bottom, for possible 4mm drain holes.
Does my measurement coincide with yours? Did you drill on the back side & countersink just a bit?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #14 of 135 Old 01-12-2018, 11:35 AM
1st Gear
 
Join Date: Mar 2015
Location: Colorado mountains
Posts: 76
pdwestman, I got 392 mm/15 7/16 inch from the top of my fork lower to the top of the step at the bottom inside. The step seems to be about 2mm high, so the depth to the true bottom ( where the Oil Lock sits) would be a more like 394-395. Mine's a 2008, but I'm not sure if that accounts for the difference in measurements.
I did drill on the back side. Not sure if you'd call it "countersinking", though; I used an endmill to just get the surface where my screw and washer would sit flat. The lower wall is pretty thin (about 3mm, as far as I can judge), so I took off as little as possible. I did end up drilling into that step on the outer circumference of the bore, but I don't think that'll hurt anything.
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Conrad Long
'08 KLR 650
'96 R1100RT
'94 R1100RS
'75 XS650B
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post #15 of 135 Old 01-21-2018, 08:14 AM
4th Gear
 
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Join Date: Aug 2009
Location: New Hampshire
Posts: 1,063
Installed LED running lights

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Ageing Gracefully



2017 Yamaha XT250
1990 Honda NX250 (Green/White)
2011 Kawasaki KLR 650 (Orange & White )

My KLR Page..http://www.powers31.info/2011_KLR650.htm

Mod's to KLR:
Power socket, L.E.D. Battery Indicator, Camera bag holder
Custom Saddlebag frames .
Louder horns, Firstgear Onyx tail bag.
Custom Aluminum Skid Plate.
Cut down seat with Custom pad.
Go Pro Camera mount.
Doo-Hicky
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post #16 of 135 Old 01-21-2018, 08:56 PM
1st Gear
 
Join Date: Dec 2017
Location: Socal
Posts: 24
I pulled my clutch cover to try to fish out a doohickey piece and replace the gasket. I found a piece of the spring, but not DH piece. I pulled the clutch plates and specked them while I was there. Need to purchase waterpump gasket.
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post #17 of 135 Old 01-22-2018, 11:51 AM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
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luckyramu,
Hoping that you haven't re-installed the clutch cover yet. Have you seen this thread? Kind of a map to search for 'buried treasure'.

http://www.klrforum.com/344697-post8.html
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #18 of 135 Old 01-22-2018, 08:02 PM
1st Gear
 
Join Date: Dec 2017
Location: Socal
Posts: 24
Quote:
Originally Posted by pdwestman View Post
luckyramu,
Hoping that you haven't re-installed the clutch cover yet. Have you seen this thread? Kind of a map to search for 'buried treasure'.

http://www.klrforum.com/344697-post8.html
TY PWWestman,
That diagram is completely helpful. I'm losing my patience, as I've been fishing for two hours so far. I will concentrate on well area #2 and take some more time. Thanks again for the picture.
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post #19 of 135 Old 02-02-2018, 05:47 PM
1st Gear
 
Join Date: Mar 2015
Location: Colorado mountains
Posts: 76
I did end up installing the Cogent Dynamics damper kit (with springs and spacers). Went together pretty smoothly. I did a dry run, then assembled the forks. The only anomalies were my preload gap was 6mm, vs the 9-11mm they list as normal, and one of my "oil lock" pieces (using Chilton's nomenclature: the plastic gizmo at the bottom of the damper rod) didn't fit into the bottom of the slider tube. The two looked identical except for color, but one would fit in the bottom of the tube, and one wouldn't. Of course the "oil lock" is only available with the damper assembly. Now waiting for some nice warm weather (I've heard it called "Spring", but only know it as the gap between winters) so I can go riding.

Conrad Long
'08 KLR 650
'96 R1100RT
'94 R1100RS
'75 XS650B
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post #20 of 135 Old 02-02-2018, 08:31 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,687
Liftrat, There is a name I haven't seen pop-up in awhile.

I'll suggest that the reason your preload if slightly different is because of your supplied rider weight/riding style/listed accessories & baggage (or lack there of) on your order sheet.
Any chance that you measured the Depth to the bottom of the lower leg to possibly install oil change drain plugs? I thought that I measured 397 mm on one customers forks, but now question my note.

I installed the front fork Cogent DDC's & springs/spacers and Moab rear shock for a customer earlier this winter after re-greasing steering bearings & all rear suspension bearings. He lives 120 miles away.

He called yesterday and again today to say how much he appreciates my / Dave Pelletiers advice on which suspension company to support. He brought the bike in with thoughts of using Progressive Suspension parts. Thanks Dave, I mentioned your name when parts were ordered from Cogent.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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