Kawasaki KLR 650 Forum - Reply to Topic
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

Thread: 1990 KLR Tengai Resto-mod.... Maybe Reply to Thread
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  Topic Review (Newest First)
02-03-2020 07:56 PM
ironranger88 While I wait for the doohicky o ring to come, i got a few other things done! I installed a 240V/50amp outlet in the garage for MY NEW WELDER! Horray protects! NO, it's nothing special.. I went with a Harbor Frieght Titanium mig 170 (becuase you cant beat them for the price) especially used for $200... seriously, that's a steal for what I need it for. (Really small projects)

I was able to weld up my blinker bracket! Everywhere I brought it, they wanted $75 min to $100 to repair that thing. What a croc. Its definitely good enough. Got the rear blinkers mounted up (still working on fronts)
Found the rear caliper shark fins from a gentleman in Virginia (on eBay) who sold the pair to me for $40 (little pricey, but their hard to find without paying $150 shipping from GER). THEY LOOK GREAT!
Got my clutch cable in from Latvia with some wonderful post cards they sent! EBayers can be nice some times..

And finally the rubber mount for the front fairing came in from Taiwan! I dont know why it was a hard part to find, but apparently they sent me two! So if anyone else needs one, it's in Phoenix.


Anyone know of an idea for the rubber mounts for the wond screen or something I can use to dampen the vibrations in it? Its very vibratey.... (oh, previous owner drilled special holes to jerry rig the front, so it's got lots of speed/wind resistance holes in the front) haha
01-31-2020 10:37 AM
ironranger88
Quote:
Originally Posted by pdwestman View Post
The O-ring on the doo-hickey adjuster locking bolt has failed. LH cover will have to be removed to replace that o-ring.
NO KIDDING! Hooray easy fixes! I've got one ordered and am happy that's all.(cause I couldn't find the plastic thing) thanks for the quick reply.

I love this bike. Just took it on a 30 min ride through a wash in Phoenix. What a fun morning.
01-31-2020 10:33 AM
pdwestman The O-ring on the doo-hickey adjuster locking bolt has failed. LH cover will have to be removed to replace that o-ring.
01-31-2020 10:26 AM
ironranger88 Wait a minute... It's not "leaking" it looks like it's supposed to seap from that seal.. what is that?
01-31-2020 09:55 AM
ironranger88 Repainted the exhaust this week and bought the wrong front pipe guard by mistake. Actually turned out to be a happy little accident, becuase after some headache of herry rigging it to fit with local hardware store rubber and spacers, it actually looks ok.

Woke up this morning to a good oil leak after putting a new o ring and real on the front sprocket shaft. Sad day, but after investigating , it looks like it's actually leaking from this little rubber thingy here. Going to have to see what it takes to replace that.
01-31-2020 09:31 AM
ironranger88
Quote:
Originally Posted by eamartin View Post
Quote:
Originally Posted by ironranger88 View Post
So, after putting a few hours of crack stopping and reinforcing the belly pan/skid plate/rock guard.... I realized that it missing a HUGE SECTION of it. lol! OOOPS Also, It's not going to fit with the engine guards... SO, back to the drawing board.

One: I redo the metal work to extend back further to attach the bottom (Maybe..) I'm going to have to get some aluminium sheet metal and do it right. OR!

Two: Get one of the aftermarket ugly ones... Which would be easier... Which means, I'll probably do that!

Does anyone have any suggestions on skid plates that will work with this weird Double front attachment point?

ALSO, do the 08 and later side fairings fit the older models? THANKS
I'd like crash bars to protect the side fairings on my Tengai but the the Tengai belly pan covers access to the attachment points, as you have discovered. No off-road for me so I'd like to retain the Tengai's cosmetic belly pan. A dilemma for us both.
Quote:
Originally Posted by GreatWhiteNorth View Post
Those look like Dirtracks crashbars? Just going thru same issue. I took off a Hyde Racing skidplate, fitted a Gen 1 SW-Motech skid plate that I modified to work with 'em. I like how it rotates down, pivoting on the forward mounting bolt (making for easy cleaning). I cut the bracket in half, to space the sides further apart to fit around the crash bars (90mm wide). That required drilling a 2nd hole in each bracket half to mount, and I had to reduce the diameter around the (long!) mounting bolt, so it doesn't interfere with the weld radius of that lower diagonal support tube on the forward crashbar mount. Hopefully you can see what I mean in these pics:


A bit of extra work making it fit for sure. These skidplates don't offer as much protection as some others (don't stick up far in the front).


For comparison, here is an unmodified bracket, same skidplate on another Gen 1 I have. Note the larger diameter around the mounting bolt - that will contact the adjacent weld radius on Dirtrack crashbars:
Nice, I'm not sure, but yes, they are dirtracks, so.. think I'm just going to keep it naked for now. Really good fab work man, it looks like it was meant to be that way! I'll def reference this when I do my own.


If I really decided to do some off roading, ill have to revisit. I really do like the plastic, it looks great, but It sure doesn't look like it does any protection. I agree. Good thing mine is garbage anyways!! lol I'll tool around and see what I come up with. When I actually decide to invest in a welder, I'll probably end up fabbing an aluminium version for myself. what a pain!!! I love it.
01-31-2020 08:05 AM
GreatWhiteNorth Those look like Dirtracks crashbars? Just going thru same issue. I took off a Hyde Racing skidplate, fitted a Gen 1 SW-Motech skid plate that I modified to work with 'em. I like how it rotates down, pivoting on the forward mounting bolt (making for easy cleaning). I cut the bracket in half, to space the sides further apart to fit around the crash bars (90mm wide). That required drilling a 2nd hole in each bracket half to mount, and I had to reduce the diameter around the (long!) mounting bolt, so it doesn't interfere with the weld radius of that lower diagonal support tube on the forward crashbar mount. Hopefully you can see what I mean in these pics:





A bit of extra work making it fit for sure. These skidplates don't offer as much protection as some others (don't stick up far in the front).



For comparison, here is an unmodified bracket, same skidplate on another Gen 1 I have. Note the larger diameter around the mounting bolt - that will contact the adjacent weld radius on Dirtrack crashbars:

01-31-2020 05:49 AM
eamartin
tengai belly pan

Quote:
Originally Posted by ironranger88 View Post
So, after putting a few hours of crack stopping and reinforcing the belly pan/skid plate/rock guard.... I realized that it missing a HUGE SECTION of it. lol! OOOPS Also, It's not going to fit with the engine guards... SO, back to the drawing board.

One: I redo the metal work to extend back further to attach the bottom (Maybe..) I'm going to have to get some aluminium sheet metal and do it right. OR!

Two: Get one of the aftermarket ugly ones... Which would be easier... Which means, I'll probably do that!

Does anyone have any suggestions on skid plates that will work with this weird Double front attachment point?

ALSO, do the 08 and later side fairings fit the older models? THANKS
I'd like crash bars to protect the side fairings on my Tengai but the the Tengai belly pan covers access to the attachment points, as you have discovered. No off-road for me so I'd like to retain the Tengai's cosmetic belly pan. A dilemma for us both.
01-30-2020 05:37 PM
pdwestman A Moose or Ricochet aluminum skid plate is held on up-front by a large U-bolt & 2-4 clamps below the gear shift & brake pedals. I use rubber donut holes cut from rubber belting or tires or mud flaps to space the aluminum plates down just a bit farther & reduce vibration noise. I do wish the drain plug holes were smaller diameter & the plates were 3 inches longer to the rear.

The OEM plastic 'air-dam' won't protect the engine from tall rocks or long rocks that get stood up by the front tire!
01-30-2020 10:27 AM
ironranger88 So, after putting a few hours of crack stopping and reinforcing the belly pan/skid plate/rock guard.... I realized that it missing a HUGE SECTION of it. lol! OOOPS Also, It's not going to fit with the engine guards... SO, back to the drawing board.

One: I redo the metal work to extend back further to attach the bottom (Maybe..) I'm going to have to get some aluminium sheet metal and do it right. OR!

Two: Get one of the aftermarket ugly ones... Which would be easier... Which means, I'll probably do that!

Does anyone have any suggestions on skid plates that will work with this weird Double front attachment point?

ALSO, do the 08 and later side fairings fit the older models? THANKS
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