Kawasaki KLR Forum banner

101 - 120 of 136 Posts

·
Registered
Joined
·
9 Posts
Happy Holidays Johnny,long time no chat, still looking for the ir lights, front/back. also a desert cammo seat or one that needs reupholster. mine is new but black and what other parts?
Got bikes for sale?

Thanks

Carlos
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #103
Back at it again! I got new rim strips, Heavy Duty inner tubes, and Dunlop D606 tires installed. The wheel bearings seemed a bit rough even though the bike only has 566 miles on it. The sleeve between both bearings was off center a bit and the axle bolts didn’t look great. I replaced all 4 bearings, replaced the sprocket bearing, the cush drive, and cleaned up / lubed (marine grade grease) up the axle bolts. I also painted the last of the parts.

I disassembled the front forks, cleaned them, replaced the seals, and put in some Bel-Ray 15 weight oil. One of the forks would get stuck about half way compressed with the springs out and was almost impossible to separate the top from the bottom. Once I got everything cleaned up I couldn't get them back together. They must be bent. Next weekend I’ll get another fork and do it again. That’s the only thing I’m waiting on to get a rolling chassis together.
 

·
Registered
Joined
·
9 Posts
Wow, you sure are at it again, like to see some pics, man, can you help me with the ir lights frnt and rear, last time you were moving stuff from up north, also a seat even if it needs reupholster, mine is new black, a front wheel, and the tool box by the back seat.


Thanks

Carlos
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #105
Started getting the frame together today. Besides the basic assembly I added a new ignition. The USMC version had the key epoxied in. Obviously without that a Marine would lose it in about 2 seconds. Also need to rebuild another fork. The one I ordered was for the right, which I already have.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #106
Got the rear rack, rear fender, taillight, kickstand, inner fender liner, and tool box on. Just waiting on the paint to dry on the other front fork and it’ll be a roller.
 

Attachments

·
Premium Member
Joined
·
6,817 Posts
I find your use of a Upper fork tube guard between upper & lower triple clamps 'very interesting'.

I agree that it is Great that you understand the importance of protecting even the unused portion of the upper tubes.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #108
I find your use of a Upper fork tube guard between upper & lower triple clamps 'very interesting'.

I agree that it is Great that you understand the importance of protecting even the unused portion of the upper tubes.
It’s actually a piece of thin pvc pipe. They came with the USMC bikes. I believe it was to help cover the shiny forks for tactical reasons. The original ones were green so I obviously painted them tan.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #109
Got the latest front fork on, new fork boots, front fender, and fender bag. I also set the steering neck bearings and attempted to get the rear axle bolt in. I’m still having the same issue. I finally took the rear wheel off and noticed that the sprocket side wheel bearing had the incorrect inner diameter. The axle bolt wont fit. I just replaced both wheel bearings and sprocket carrier bearing with a set of either Moose Racing or All Balls. I guess I need the OEM one. Got the original fender bags reproduced by Storm Industries. He’s done all of the fender bags for me so far and made a few really cool tool rolls.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #110
Found a new set of rear wheel bearings in my parts bins. Replaced the incorrect smaller diameter bearing and got the rear wheel and axle bolt on. Fought the grips on to the handlebars and put on the handlebar brush guards. I was going to rebuild the carburetor but just realized I was sent the rebuild kit for the Gen 2 KLRS vice the correct Gen 1.
 

Attachments

·
Premium Member
Joined
·
6,817 Posts
The only difference I'm aware of in Gen 1 vs Gen 2 aftermarket carb kits would be Main Jet size. Couldn't you clean your old main jet & re-use it?
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #112
The only difference I'm aware of in Gen 1 vs Gen 2 aftermarket carb kits would be Main Jet size. Couldn't you clean your old main jet & re-use it?
The carb from this bike was rough. I’ve got a main jet on another carb I could use.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #113
Finally got the engine in. Just need to clean it up and replace the hoses. Tomorrow I’ll get the wiring harness in. I also cleaned the last 4 carbs for the bikes I have left (only 3). Just waiting on the rebuild kits from Eagle Mike.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #114
Just did a few basic things today. I replaced the engine filler cap and drain plug with ones from Eagle Mike. I installed the exhaust (painted with high temp paint) with all new hardware for the exhaust shields, replaced the exhaust pipe gasket, and muffler join gasket. I put in a new oil filter and brand new cooling system hoses. I also installed a new UNI air filter using no toil air filter oil and paste for a better seal and then cleaned up the rear brake caliper and put in some new EBC brake pads.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #115
Finally got the wiring harness into the bike. Just need to get the headlight bracket in to connect the front end wires. Just got my custom made stencils in. I had a company reproduce them from measurements of the existing ones. I basically just scrap them off with a razor blade. Most military vehicles had the stencils spray painted on but these were just vinyl. They are really durable and a have a matte finish.

Yesterday I rebuilt two of the four carbs I had stripped and cleaned a few posts back. My bike wouldn't start so I took the carb off, cleaned it, and rebuilt it. Now the bike runs better then ever.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #116
Got the rear brake in with new EBC break pads. Just need to get the master cylinder cover on and brake pedal installed. Still contemplating if I want to do the doohickey. The engine only has 566 miles on it. Also got a few things buttoned up on the wiring harness. I was able to get the radiator and fan in. Just waiting on one cooling hose and a new Deka sealed battery.
 

Attachments

·
Premium Member
Joined
·
6,817 Posts
That mid generation of doo-hickey was prone to breakage if not kept properly adjusted.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #118
That mid generation of doo-hickey was prone to breakage if not kept properly adjusted.
Got ready to get it done yesterday but realized I was missing the torsion spring and rotor holder wrench. Ordered form Eagle Mike. Should be here in a few days and I'll get it done.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #119
I moved the rear turn signals to front (since they are shorter) and used the stalk delete (from 3D Cycle Parts) on the front signals and moved them to the rear (won’t break in a layover). Put the on the X-ring chain, rear brake pedal, rebuilt carb (capped vacuum port for raptor fuel petcock direct flow and Eagle Mike screw upgrade to hex head), cable-less choke (from stead engineering), handle bar controls, front brake, and the wiring harness is done. I also lubed and installed new throttle cables, speedometer cable, and clutch cable I got the headlight / gauge housing in and started to route the front harness through there. I also replaced all coolant hoses, new coolant, and over flow bottle. I also got the seat reupholstered in tan marine grade vinyl. It’s the only thing on the bike I didn't do myself.
 

Attachments

101 - 120 of 136 Posts
Top