2008 KLR650 Lightening Project

[SamM]

Have you picked out your headstone comment? My recommendation is "He optimized everything."
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Weldangrind

Wow, I'm not in any hurry to do that. Besides, I don't care what it says. No funeral or any of that for me. Roll me into a ditch and move on.:wink:

I got my XR650L down to a weight of about 300 pounds, with an empty fuel tank. :wink: Getting a KLR650 down to a weight of 300 pounds is a very impressive, and ambitious project. Have you had a chance to weigh the bike?

Spud

Yes, I weighed the bike, as pictured but with a JNS skidplate and a GSXR1000 titanium muffler and it weighed 345.2lbs. That was with an empty fuel tank. The smaller 5.5gal IMS fuel tank will drop 12lbs but the Versys engine weighs 7lbs more than the KLR engine. I'll drop another 10lbs with a Li-ion battery and then there are plans to cut more weight later. I may ditch the airbox and the steel kickstand. The stock KLR650 rear fender might get swapped out for a much smaller and lighter KX450F rear fender. The front fender has already been changed for the KX450F unit. The subframe may need to be changed a little to fit the KX fender but I think I can fab up something that looks pretty good.

For longer trips that require luggage, I'll use a Giant Loop or a set of Pelican hardbags that I have. This bike is being made to do everything from singletrack to interstate touring. I'd like the first test to be an Iron Butt ride early next year. Probably the 1000 mile ride in 24hrs.

SamM

[MICRider]

Hmmm... 1000 miles on a KLR in 24 hours? I'm wincing at the thought of it!

[SamM]

The custom Renazco +2 Rally seat makes a huge difference. Even though I have basically turned my KLR into a very large dirtbike, it's still pretty comfortable. It's way better than my KTM 950 ever was. The KLR also has footpeg drop brackets, rubber mounted handlebars and my special bungie cord cruise control. Plus it has KX450F USD forks on it. No comparison to the stock cartridge forks. When I get it back from the builder, I'll be adding the Magura hydraulic clutch kit for a Versys. Since it will have the Versys engine the kit will bolt right up.

The Dunlop 606 knobbies are gone. Replaced by Heidenau K60 50/50 dualsport tires.

I've already done a 600+ mile day on it. With the new parallel-twin Versys engine, 1000 miles will be a piece of cake.

SamM

[MICRider]

Good stuff Sam, enjoy the ride

[SpudRider]

Originally Posted by MICRider

Good stuff Sam, enjoy the ride

X2!

Spud

[SamM]

Thanks guys! I think it's going to be a cool bike!

[SamM]

Just thought I'd share a couple more pictures of my '08 KLRE650ie. Not much progress to report. We are still looking for a header and a few other parts. I don't imagine that I'll be rding it this season. My plan is to rework a few things this Winter and lighten it even more. It should be finished and rideable next riding season. It's been tough being without a bike this year.

SamM

[MICRider]

Versy's mill looks pretty comfy in there Sam 8). The fabwork on the lower cradle is beautiful, whoever is doing that is an artist!

[SpudRider]

Originally Posted by MICRider

Versy's mill looks pretty comfy in there Sam 8). The fabwork on the lower cradle is beautiful, whoever is doing that is an artist!

I agree on all points. Thanks for posting the update, Sam!

Spud

[FastDoc]

Sam would have been the man to put an XR engine in the Beeza! :wink:

[SamM]

Thanks guys!

We are so excited about this project. I'm not at liberty to reveal the builders name yet, as he has work to do and simply doesn't have time to answer the phonecalls and many questions that he would no doubt receive. You may have read about the other KLRE650 builds on AdvRider. We have some new ideas and will approach several things somewhat differently than the other builders did. The main issue is the airfiltration. We have a solution to that problem. The other problem is the close tolerances between the engine and the fuel tank. Again, we have a solution to this problem. Our solution makes a few other things possible.

I have some plans to strengthen the frame with a few metal sleeves inserted into the stock KLR tubular frame sections. My bike will require a good bit of work after I get it back. One of the reasons this has taken so much time, is because he is considering releasing a kit to do this swap to any model year KLR. That may or may not happen! I honestly believe this motorcycle could change the dualsport adventure motorcycle market.

FastDoc,
What is a Beeza?

MICRider,
That engine looks great in there doesn't it! That's why this is such a natural conversion. He really knows this stuff. He has a conversion shop and specializes in SUV diesel conversions. He wants to get his hands on my Diesel KLR project next and I may let him have this to work on later. I just bought it.

[MICRider]

A diesel Wrangler you say? That would be an interesting machine!

[SamM]

I'm thinking about it. The stock 4-banger only has 125,000 miles on it. Probably good for another 200,000 miles before anything really needs to be done with it. I'll upgrade the axles and other equipment before a new engine goes into it.

SamM

[FastDoc]

Beeza. BSA. a 1968 441 Victor in my case. See threads about it and it's motor's demise in this sub forum.

[SamM]

Sorry! Should have known BSA. I did see your thread.

SamM