ImNoSaint's KLR Build - Kawasaki KLR 650 Forum
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post #1 of 28 Old 04-27-2016, 03:45 PM Thread Starter
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ImNoSaint's KLR Build



The initial tear down showed the good, bad and ugly. The good being the integrity of the main wiring harness and electrical in general, a new(ish) battery, a well-tended and stored fuel system and carb, good rubber - Shinko Trail Masters, and it runs perfectly. All fluids are fresh and level. The bad is the shift of a fairing mount on the radiator reserve tank frame from a side hit of a fall - nothing serious, just a bit out of whack where the RH side fairing doesn't mate up to its mounts in a factory fit. The frame is fine. The left front turn signal has been supplemented with electrical tape. The ugly is the air filter which I doubt has ever been changed, along with the cosmetic scar-tissue of a previous rider too short for this bike.

The KLR has a Caribou (Pelican Case) pannier system that is lockable. The system is design to have the cases breakaway in the event of a spill since the construction of the cases is more durable than the frame to which they're mounted.



The engineering of the mounts needs some new hardware and a smack or two with a rubber mallet, but it won't take much to restore the ride and vibration integrity back to this luggage system. The case pictured above took the worst hit but it's still viable and waterproof.

The rack works with a replacement for the KLR stock luggage rack aft of the seat.



I'll be mounting a third Pelican case on this rack, moving the small tool box within it.

The front forks have been fitted with an Eagle Stabilizer. Bonus.



The stock front fender has been replaced as well with A Polysport UFX free flow fender.



Plans include crashbars, upgraded skid plate, Progressive suspension, top mount Pelican case, a throttle lock, a Ram mount, a 12V/5V charging socket and USB, fog/driving lamps and an auxiliary marine fuse box.

I'll be changing the color scheme as well, tone down the factory color to something more khaki, black and grey.
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post #2 of 28 Old 04-27-2016, 03:49 PM Thread Starter
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Pannier Repair



The pannier system is from Caribou with 35 liter Pelican cases that straddle a steel, powder-coated frame. This is an older design compared to Caribou's latest offerings, but still features lockable cases and lockable quick-release systems for case removal. The system is expensive, and factored heavily into my decision to purchase this particular KLR.

I've been working with Pelican cases sine they came on to the market. They're a mainstay in film production and photography and I've had at least dozen in various sizes to contain delicate and expensive film gear, handled by the world's worst airline baggage tossers, bellmen, shipping companies and failed tie-down straps at freeway speeds. Despite all the abuse, the cases never failed and their contents were never compromised.

The Caribou system has been engineered to have the cases break away in the event of a collision since they're more stout than the frame upon which they're mounted. This system has been beaten up considerably, with bent cleats and a locking mechanism that barely engages on both sides. I was lucky to get everything home on my initial ride back from buying the bike.

On further inspection, I found the cleats to be sprung out and the quick-release mechanism barely engaging. The fix included bending the steel cleats back into round and modifying the adjustable quarter-inch bolt that engages the levered quick-release.



Seen above, disengaged, the locking mechanism pulls up away from the frame, lowering a compression arm below, attached to which is the adjustable bolt. The existing bolts were at their thread's extent and couldn't be adjusted any farther. I replaced both sides with longer bolts and fastened a large fender washer with a locking nut to the top of the bolt that screws into the level and locks with a second bolt. I bent the washer to hug the frame when it's engaged.



Now there's ample compression against the frame with no more rattling around.
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post #3 of 28 Old 04-27-2016, 04:09 PM
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i like your plans.

i just purchased the same bike...although yours seems to be in much better shape.

i thought the same thing about the colours! i was thinking a 2-tone brown...be interested to see what colours you end up with. paint the tank and fairings the same?

thanks for posting.
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post #4 of 28 Old 04-27-2016, 05:10 PM
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Air Filter,

ImNoSaint,
Just a footnote about the air filter, the preferred air filters are Cleanable / Re-oilable / Re-usable foam. They don't need to be replaced, just re-serviced. And replacements must be Oiled before use.
It is great to have a freshly serviced spare in a zip-lock bag.

Totally grungy on the outside is perfectly ok. As long as it was properly oiled when the bike was new it should have kept the dust out of the engine. A dry foam or a dry K&N is bad news.

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post #5 of 28 Old 04-27-2016, 06:04 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
ImNoSaint,
Just a footnote about the air filter, the preferred air filters are Cleanable / Re-oilable / Re-usable foam. They don't need to be replaced, just re-serviced. And replacements must be Oiled before use.
It is great to have a freshly serviced spare in a zip-lock bag.

Totally grungy on the outside is perfectly ok. As long as it was properly oiled when the bike was new it should have kept the dust out of the engine. A dry foam or a dry K&N is bad news.
Thanks for the tip. Nothing like the smell of filter oil. I cleaned the element and it came out just fine.

Quote:
Originally Posted by tjtj View Post
i like your plans.

i just purchased the same bike...although yours seems to be in much better shape.

i thought the same thing about the colours! i was thinking a 2-tone brown...be interested to see what colours you end up with. paint the tank and fairings the same?

thanks for posting.
Thanks for your response. I shot the bike over the weekend and will post about it. Interested to know what you think.
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post #6 of 28 Old 04-27-2016, 06:09 PM Thread Starter
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Naked



Forrest Gump would have something to say about buying a used motorcycle, much like a box of chocolates. Unless you're kicking tires with an 8mm socket in your pocket and the the owner's permission to disrobe the bike, you never know what you've got until you've got it home and have it unclad.

I posted earlier about an initial teardown, leaving the headlight/instrument cluster faring still in tact along with the LH radiator shroud. It all came off this past weekend to prep and paint all the plastics.

A couple of notes: Large wood screws are no substitute for proper, specified and engineered hardware. There's one instance of these beasts force-threaded into the embedded nuts on the rear frame crossmember to which the rack is attached. This kind of quick and dirty fixing gives me the shivers. And it pisses me off. A trip to the hardware store would have taken care of the problem, even if it were a roadside repair (which, I can't imagine it was).



Always a good idea not to mix SAE and metric. Hardware standards are used to keep everything accessible with a minimal amount of tools to do so. Also, before taking on a task like this, it's not a bad idea to have new OEM replacement hardware, especially rubber wellnuts to replace all the disintegrating rubber isolating mounts, not to mention the windscreen, as well as all the slipshod hardware used by PO's, like wood screws.

If you're thinking about adding a switch or a 12V socket to the dash, it's good to know what's behind it.



There are three dimples that make up little triangles on each side of the instruments that might suggest factory points for switches to be mounted. They're not. They've just there to break up the space a bit since the backside of both areas butts against the cluster frame.

Just above the dimples is a flat space that's not obstructed with enough space to mount an accessory switch on either side.



I'm going upgrade the stator and add a Blue Sea Blade six circuit fuse box with a negative bus to handle the accessories. Since there's no space beneath the seat I'm considering a location high on the coolant reservoir brace, the highest point I can find on the bike without mounting it to a faring.
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post #7 of 28 Old 04-27-2016, 06:17 PM Thread Starter
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Painted



Bleeding red (as in Honda), it was a switch to ride something green. That's not to say that Kawasaki is inferior to Honda, but we all know how we are when it comes to brand loyalties, and that's whack. And that's not the only reason I decided to change the paint scheme on the KLR. I really like the khaki one featured on this KLR650 forum page header.

I also like the factory paint on the new KLRs, not so much the digicamo, but the blacked-out bikes with simplified graphics, not to mention the few older camo-rattle-canned KLRs I've seen on the interweb.

I played around a bit on Photoshop to see what a khaki scheme might look like on the KLR's lines.



I decided to make some changes, going simplest form first. I didn't want to change the tank color so I reversed the black and gray motif, going black on the headlight cowl fairings, and gray over the silver radiator fairings.



All factory graphics were removed using a heat gun and Goof-Off to clean up residual glue. The cladding was then removed, cleaned and degreased, buffed with steel wool, washed and tacked and suspended on a line. Three colors were shot; flat khaki on the tail-light shroud and side panels under the seat, gray on the radiator covers, and flat black on the headlight shroud fairings.





The Krylon products worked well, applied in ideal conditions. They advise that the coating becomes chip-resistant in seven days. Not being that patient, I rode three days later and got caught in a hail storm. I thought for sure I'd be reshooting everything, but it came out without a scratch.
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post #8 of 28 Old 04-27-2016, 06:35 PM
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yup definitely an improvement! i like the 3 colors...seems to work well.
did you consider doing the front fender grey?...black looks good tho.

krylon...good tip.
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post #9 of 28 Old 04-27-2016, 06:36 PM
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Looks good!
But your 'bleeding Red' idea was "Cool"!

Glad that you didn't get any storm damage.
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post #10 of 28 Old 04-27-2016, 07:20 PM Thread Starter
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Quote:
Originally Posted by tjtj View Post
yup definitely an improvement! i like the 3 colors...seems to work well.
did you consider doing the front fender grey?...black looks good tho.

krylon...good tip.
I did, and khaki as well. I'm going to replace it with an Acerbis Supermoto fender so I left it alone. The gray isn't dark enough for a greater contrast against the khaki line, so I may look for a better color.
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