Tin Man's 2015 KLR Build - Kawasaki KLR 650 Forum
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post #1 of 24 Old 04-26-2016, 06:39 AM Thread Starter
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Join Date: Apr 2016
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Tin Man's 2015 KLR Build

Hey guys....picked up a leftover 2015 KLR 650 after selling my 2014 WR450. Had many bikes over the years and decided to pull the trigger on the 15 after taking my dads 2014 klr for a ride last year. Gone on the days of riding in pits, jumping off dunes and full throttle fire road runs.
Its time to sit back and enjoy the view and be comfortable doing it. I think the KLR will leave up to those expectations very well.

Here she is....like her predecessors....she had to be named...Tulula was the first thought that came to mind and it stuck.
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post #2 of 24 Old 04-26-2016, 07:08 AM Thread Starter
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First mod....needs tail bag for light day trips. I already had the bag sitting on my sled. Polaris lock and ride bag should fit nicely on stock rear rack of the KLR with very little work...

I figured I needed a few simple pieces of 1" aluminum tubing to make the polaris lock and ride work with their nifty fastening system. A 1" hole saw was used to cut the holes.

So it fits nicely and seems like it flows with the lines of the bike nicely.


When the SW Motech crash bars show up its off to the powdercoater for a splash of color on those brackets and other little items.
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post #3 of 24 Old 04-26-2016, 07:12 AM Thread Starter
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First part to arrive....KN Filter.....I use these on everything I have owned.

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post #4 of 24 Old 04-26-2016, 07:25 AM
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Looking good.
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post #5 of 24 Old 04-26-2016, 08:04 AM
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Location: Ontario, Canada
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will be following this build thread.
thanks for posting.
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post #6 of 24 Old 04-26-2016, 07:57 PM Thread Starter
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So just after I finished posting on here today I see a van pull up to the shop with my favorite 3 letters on it.....UPS.
To my delight the driver had my Lexx exhaust. I have to say this is by far the best bang for your buck in the exhaust department. Very high quality. I had it shipped in from Amazon.com in the US for $300 bucks after the exchange and duty. FMF exhaust was the cheapest I could find in Canada at they are pushing close to $500 now.
The black metal has a unique finish and blends with the bike well. The mid pipe has a neat aluminum spacer that fits inside and goes over stock header. The mid pipe then holds to the can with 2 springs. High temp silicone is used on all joints. I have read some reviews on this pipe and some of the complaints we about the pipe coming loose from the mid pipe and header joint. I think that may be partly the fault of the instructions as it doesn't say to use the stock exhaust clamp but rather just us silicone. I reused the clamp.
I cannot comment on sound yet and as mother nature decided to bless Newfoundland with a bit more winter. So in a few days I'm hoping to have it out for a run. Thursday the dynojet jet kit comes in and I think the bike will need it. Just by installing the KN filter and I noticed there was some decel pop that wasn't there before the filter install.
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File Type: jpg 20160426_192025.jpg (295.7 KB, 45 views)
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post #7 of 24 Old 04-27-2016, 03:31 PM Thread Starter
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Frank the UPS driver showed up again today with a package from Canadas Motorcycle....yes yes I know I'm on a first name basis with the guy now. It happens...by the end of this build I may end up being his best man at his wedding...lol.
So if you Canadian guys aren't away Canada's Motorcycle is one of the best online canadian site to buy online but you need to work to find the good stuff. I discovered a few years ago that the bike search on their site doesn't find all the parts so if I am looking for something....in this case a double bubble windscreen....its better to search by the manufacturers part number then model year of the bike. On their site there are only 117 specific parts that show up for the 08 and up klr 650. The zero gravity windscreen wasn't one of them BTW.
So here is the stock windscreen...
Attachment 8674
And here is the Zero Gravity Double Bubble in light smoke part #23-206-02
Attachment 8682

I'm hoping this will solve the buffering I am getting that hits me right in the chin when sitting on the bike at highway speed. I'm 6'1" if your wondering and I use a Icon Variant helmet.
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File Type: jpg 20160427_172738.jpg (200.2 KB, 62 views)
File Type: jpg 20160427_173808.jpg (198.8 KB, 64 views)

Last edited by Tinmaninc; 04-27-2016 at 03:35 PM. Reason: upload error
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post #8 of 24 Old 04-27-2016, 06:17 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,536
KLR650 model K&N air filter is built sort of like the 'Leaning Tower of Pizza'.
It leans Up and to the right.
If the filter body is not installed correctly the metal end cap does not fit correctly and then the filter doesn't filter completely.
Pay very close attention to your installation.

You say you lov'em. I'll not attempt to change your mind.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #9 of 24 Old 04-28-2016, 03:01 PM Thread Starter
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SW Motech bars showed up today....holy heavy. I never expected them to weigh that much. Probably because I have never has a set before. I was thinking of installing them them but I may just wait until my powder coating guy gets back to town on May 24th. I didn't want the hassle of having to remove them again but I find it very hard to just have new part sitting around waiting for installation.

I wanted to talk about customer service as well. I ordered 2 sets of SW Motech crash bars from Twisted Throttle. One set for me and one for my dad's '14. When I had placed the order a few weeks ago their site said 5 left in stock so hurry fast. I did and after a day went by I received an email saying they were out of stock. I was a little disgusted after it saying in stock and I told them how I felt. I waited two weeks like they said and emailed back...they just came in...that was 2 days ago. Today I received them. They had expressed shipped these things to me in two days. Thank you Twisted Throttle.
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post #10 of 24 Old 05-13-2016, 09:39 AM
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Join Date: Mar 2016
Location: Spring, TX
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Bike is looking awesome! Keep us posted as you continue the build.
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