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2008 KLR650 Lightening Project
Thought I would post this here, as it has been a big part of the slow down on my other project. I decided to rebuild my gas-powered '08 KLR650 after my CVT manufacturer went belly up. This has slowed the diesel bike build down to a crawl as I'm waiting for the new CVT to arrive in the US. I'm still working on the diesel bike but most of my time has been spent on the gas KLR. I need to get a bike up and running, so that I can ride this year. The Diesel KLR is getting the stock forks and brakes from this KLR. As you can see I've swapped the forks. I've also added an aluminum KLR600 subframe to the diesel build. After the gas-powered KLR is finished, I'll start back on the diesel build. Probably in a couple of weeks.
Here are a few pictures of my 2008 Lightened KLR650. Just waiting for the last of the parts to arrive. Most of the mockup has been done. I still need to add a couple of radiator mounts and to make a few inner fender mounts for the subframe. You'll notice that the bike has 2008 Kawasaki KX450F USD MX forks. These have become a bolt-on modification now since Emig Racing has released a KX/KLR conversion steering stem. It's an awesome mod. My KX forks were rebuild, revalved and resprung by MX-Tech Inc. The first picture shows that all the extra tabs have been cut from the frame and subframe. As much as possible, all the unnecessary weight has been removed from the bike. Long range plans include a Rekluse auto-clutch and to remove the rear brake lever and the clutch lever. The bike has a cycleracks.com rear rack to haul gear and the Renazco +2 custom Rally seat was the one pricey item that I had to have. The seat will make long trips much easier on my backside. The Trail Tech X2 headlight and Vapor Stealth computer will be here next week. I'll add a small windscreen to the headlight at some point. For now, I'll be using a stock 2009 KLR wiring harness but the stock '08 KLR harness is being cut to the bare minimum. The wiring on these things is crazy. It's got to go. Only the starting, charging and ignition circuits will remain. A ProCycle add-on lighting harness will take care of the lighting. My plan for this bike is to make it a do everything dualsport motorcycle. I want to tour on it but I still want the option of taking it off-road. A rear siderack system will be added to mount Pelican hardbags for longer trips. The rear rack (pictured) will haul whatever I can strap down to it for weekend camping trips. Two drybags will do for most trips. More rear suspension travel has been added with 2007 KLR650 Uni-Track linkage and a RICOR IAS (inertial) shock. It also has front and rear Galfer 'Wave' rotors. New Excel wheels are next on the list for Summer mods. The bike will soon have all new LED signals, taillight and a Halogen X2 headlight. All of the frontend parts are stock KX450F. From the axle to the mastercylinder. What do you think? How did I do? :wink: SamM Fairing mounts and subframe tabs removed. Frame painted. http://img444.imageshack.us/img444/316/cimg3449.jpg 2008 KX450F USD fork conversion. http://img689.imageshack.us/img689/6593/cimg3451u.jpg Minus the bodywork. http://img689.imageshack.us/img689/5306/cimg3485u.jpg Removed the sidepanels and mounts. This is it. Just the headlight to add. http://img686.imageshack.us/img686/8417/cimg3489.jpg |
Your KLR is beautiful, Sam! :) How much weight do you think you pared from the bike?
Spud :) |
Thanks SpudRider! :wink: I'm liking the looks of the bike a lot. Can't wait to ride it. The suspension is going to be a huge improvement.
Realistically, I'm hoping that the total weight removed is around 50lbs. The KX USD forks weigh more that the stock conventional forks but when you add up the weight of the KLR trees, KLR wheel, brake, axle etc... the KX450F parts weigh much less! Most of the KLR parts are steel. The KX parts are aluminum. If I can get it between 325 and 350lbs, I'll be very happy. Anything lower is gravy! Dry it weighed 386lbs. but that is straight from Kawasaki, so I don't know if it's accurate. The parts that I have removed include: steel handlebars steel bars ends handguards mirrors steel mastercylinder brakelines steel brakeline retainers footpegs passenger pegs side panels & mounts tank shrouds fairing fairing stay & frame mount headlight windscreen stock gauges steering lock helmet lock speedometer drive speedometer cable turnsignals radiator fan steel fuel tank KLR steel forks plastic fork boots steel trees steel steering stem KLR front wheel steel axle steel axle spacers steel brake caliper front & rear rotors inner fender KLR front fender rear rack header heatshield KLR rear shock '08 KLR rear linkage KLR chainguard plastic chain block and metal mounts KLR plastic skidplate oil drain plug Many pounds of fasteners, bags of them! The parts that I have added include: Moose Racing aluminum handlebars MR handguards folding KTM mirrors Aluminum KX450F mastercylinder braided brakelines plastic & aluminum brakeline retainers MR footpegs Trail Tech X2 headlight Trail Tech Vapor computer ProCycle LED turnsignals 2007 KLR radiator '07 fan IMS plastic fuel tank KX aluminum forks KX plastic fork guards KX aluminum trees Emig Racing aluminum steering stem KX wheel KX axle KX aluminum axle spacers KX aluminum caliper much lighter Galfer wave rotors KX front fender cyclerack.com rear rack billet RICOR IAS shock '07 rear linkage WR250X chainguard JNS skidplate magnetic low profile oil drain plug As you can see a lot was removed. Many parts were not replaced. We'll have to see what happens when I weigh it. SamM |
Everything looks great, Sam! I am sure the new forks will improve the suspension, and they look beautiful. :) The paint job is also beautiful. If you have lost anything close to 50 pounds off the stock weight, you will have vastly improved the offroad capabilities of your motorcycle. :D Please do let us know the results when you get a chance to weight the bike! :)
Spud :) |
SpudRider,
Believe it or not, that isn't paint! That's the finish of the plastic parts. All the painted bodywork has been removed. Only the frame has paint on it now. There is still much to do but I will weigh it as soon as I can. I'm starting to get very curious as to what I got it down to. All I know is that it's much easier to roll around now. Thanks for the kind words! Glad you like it! :D Here's the headlight that I just purchased. Disregard the orange! I got the black Trail Tech X2 dualsport version with the red Trail Tech graphics. SamM http://www.trailtech.net/media/light...-STT3_w750.jpg |
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Spud :) |
Sorry, I thought you meant the plastics. The factory type primer and paint was purchased from Color-Rite. They are great to work with and the paint matches perfectly. It comes in aerosol spray cans. It's a little pricey but well worth the cost.
The IMS tank also matches up perfectly with the factory Kawasaki plastics. I'm actually thinking that I may buy a 5 gallon IMS tank. The 6 gallon tanks holds more like 7 gallons and is huge. For shorter trips the 5 galllon tank would be much better and it will cut the weight. SamM |
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Spud :) |
Very very nice project.
I call my KLR650 the tractor. It doesn't even bother me at all when I drop it. Your bike is truly nice. Saving for the BMW F800GS. |
That is one sweet looking unit! Please be sure to post some pics with the headlight and signals on it once you get them all :D. I'm also very curious as to what it weighs now, looks like you have shaved a ton off of it by your parts list!
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The new Trail Tech X2 headlight is on the bike. It sat a little low so I made a small bracket to support and raise it. I also installed the stock muffler back on it temporarily. A new FMF header and a new muffler will be ordered, as soon as I decided what muffler to buy. Still looking for a good one. I'll be welding a few tabs to the frame to support the inner fender. My new welder and the steel that I need are here. Swapped my new Lincoln Electric 180 MIG for a 140. The 140MIG runs on 120V and will do everything I need to do.
Better pictures next week. It's raining and I'm at work. SamM http://img171.imageshack.us/img171/2072/cimg3499.jpg |
The headlight looks great, Sam. :) Thank you for posting all the superb photos, and sharing this interesting project with us! :D
Spud :) |
SpudRider,
Thanks for the kind words about my project. I like the positive feedback and it keeps me on track. Riding season is upon me and I need this thing on the road. The '08 is a great starting point in my opinion but this could be done with any KLR. Many consider it an entry level bike but I think it's just a great bike. For the money you can't really beat it. SamM |
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Spud :) |
'08 KLR650
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Yes, my KLR650 is the new '08 version. Here's what it looked like at 23 miles. I started farkling it the day I got it. New 19/17" Excel wheels and LED signals http://img30.imageshack.us/img30/8160/cimg0674z.jpg The new fairing and windscreen originally drew me to '08 KLR. I was riding a new KTM 950 Adventure S at the time, but was looking for something more simple and much lighter. I needed a bike to ride on long trips, so the windscreen was important. A buddy let me ride his '08 KLR650 and I really liked it. In fact, I like it so much that after a trip to Deal's Gap, I vowed to never ride the 950 again. Got the new KLR for Christmas a couple of months later. Never did like the red color, so here's the second version of my KLR. Spruce Knob, WV. Same bike. http://img36.imageshack.us/img36/9042/cimg1634d.jpg Hellbender Burritos in Thomas http://img138.imageshack.us/img138/1774/cimg1671n.jpg Cool Springs, WV. http://img138.imageshack.us/img138/4351/cimg1672j.jpg You're right about the '07 radiator. The IMS tank requires that conversion. The '08 radiator doesn't fit with the IMS fuel tank. The good part is that I easily sold the stock '08 radiator for enough ($450) to do the '07 radiator conversion (about $350). The '07 radiator needs a new screen and a new fan switch. I actually got all that for less than $350. The fairing, fairing stay, stay mount and gauges were all removed from the bike easily. All of it unbolted but the mount. I cut the mount off the frame with an angle grinder. Cleaned the frame with a sanding paddle and then repainted the frame. If you didn't know it was there, you couldn't tell. Turned out great. The gauges were sold for $200. That cash and the leftover money from the radiator paid for all my Trail Tech parts. The conversion will also need a couple new radiator mounts. I hope to finish those this coming weekend. It's all pretty much straightforward stuff. The electrical part of the project will be the worst. These bikes have way too much wiring. The safety interlocks will not be reused. Well, maybe for a little while. I wanna RIDE. The vacuum operated fuel valve was ditched long ago, just like the sidestand safety switch. Leave it down once and you'll never forget it again. Back in the old days we didn't have those anyway. I like simple and light. This bike is an exercise in weightloss. I'm looking to remove much more, if I can! The heavy muffler and stock header are next on the hit list. Again, thanks for the kind words Spud. I just want to say that I've enjoyed reading about your Zongshen. I have one of those also. You've done some great mods there. Sorry for the late reply to your post. Had a long weekend at work. :wink: I'll try to take some good pictures of the bike tomorrow with a better background. I got a little more done today. The headlight is raise up and secure and the new KTM Military mirrors are on it. Nice! SamM Re-adjusted and raised headlight mounting bracket http://img535.imageshack.us/img535/1045/cimg3517.jpg |
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