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New threads are a great move for these projects. I'll suggest to remove most top end and side stuff while still in-frame.
There are a few bolts hiding under things in the top end. Never force anything, look at the books again.

Loosen the lower suspension rocker pivot before trying to remove lower cases from the frame.
 

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Discussion Starter #162
I'll suggest to remove most top end and side stuff while still in-frame.

There are a few bolts hiding under things in the top end. Never force anything, look at the books again.
I had planned to do that. I thought about buying an engine stand from Rocky Mountain, but decided it would be less expensive and easier to disassemble it in the frame.

I’ve also read a few threads, and know there are some hidden or tricky bolts to get to. So, I’ll keep your advice in mind and if in doubt, stop, reflect, research, and post any questions during those challenging methods.

I’m actually taking this build down to the frame as I am going to be pulling some electrical wiring for custom additions. Plus the front end work. Full fork rebuild and a look at the steering bearings. Might as well since I’m there.


Loosen the lower suspension rocker pivot before trying to remove lower cases from the frame.

Thanks for the reminder. I’m going to pull the swingarm again and that pesky top linkage section you just mentioned that usually rusts solid. I’ll replace any bearings, bushings, or seals that need it at that time. Plus plug those troublesome holes. Not sure if I’ll put in zerk fittings, tap for bolts, or just use silicon to plug them up. Since I’ll have it all apart, guess I can figure it out then.

If you see anything in the new thread that I’m missing, or needs to be looked at, hope you and the rest will point out the errors to me.
 

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hmmmm; 9,000 minus 6500 = he spent 2500 on mods.....I've spent more than that on mine and would do it again. I think the OP will spend that on engine mods alone...

2 cents
Dave
 

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Discussion Starter #165
Honestly, I’m keeping track of the expenditures, but haven’t totaled them up as of yet. It’s a mix of farkles, upgrades, tools, etc.

The video is actually kind of meaningless as he’s just listing the basic upgrades. He - as he stated - didn’t even touch the suspension.

Then again, I didn’t buy new. I bought a used KLR because I knew I was going to upgrade it. I had two choices ... buy new with some minor farkles or buy used and upgrade the suspension and engine.

I went a bit off track with the engine though. And I bought tools and additional farkles not I my original budget. My original budget was about $8,000 including the purchase of the KLR ($3000). I put $2300 into the front end along with some tools and parts to rebuild it. That still left $2700 for the engine upgrade alone. So, when it’s all finished, I’ll figure out what I actually put into it. Plus what I’ll have left to do.

This motorcycle isn’t just about money to me though. I fully expect to enjoy the break down, upgrade, and rebuild of the bare bones. I expect to enjoy the work on it as much as I will the ride on it. Nor does it matter if other motorcyclists thing I’m a loon to do it as it’s not cost effective. As if only the money matters. In the end, this KLR650 will be my KLR650. There are others out there. Some better. Some worse. All that will matter to me is that this one is mine.

I hope you enjoy your as much. If it’s just transportation to you, well I’ve been there too, but I’ve moved beyond just riding to get from point A to point B. If this is the case, I do hope you too will get past the ... it’s just transportation phase. Life is too short. Enjoy what you can while you can because you never know where the road/trail/etc. will end.
 
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