2008 Kawasaki KLR456 Diesel Motorcycle Project

[FastDoc]

You sir, have the inventive spirit, and Godly heart that made America great. Keep it up.

[SamM]

Thank you very much for the kind words FastDoc.

I try to give back what I can but I'm not nearly as good at it yet as some I know. There are some really wonderful people out there. I try to learn as much as I can, whenever I get a chance to spend time with them.

Motorcycles are something that I am really passionate about. In the future, I think we will see more and more electric motorcycles as the technology moves forward. Spending upwards of $8000 on battery packs that get me 60 miles isn't something that I'm ready to do just yet. The ZERO Motorcycles S & DS models are very interesting to me. Their 60 mile range would work for me as a commuter bike but not much more. GREEN buying incentives in my state drop the $9950 price to $6450 with no sales tax but I still need to spend the $9950 upfront at the time of purchase. As the batteries get better and competition drives the market, we'll see more and more of these hit the market and the prices will get better.

I can't wait!

SamM

[SamM]

My engine will be here next week. I have my money piled up and I'm ready to order it within the next couple of days. The cost was to be around $800 but I got a price reduction and it came in at $745 shipped to my door. Can't wait to get my hands on it!

There are still a few extra KLR parts that I need to finish the rolling frame. These are the rear shock linkage bolts, outer axle adjusters, a cushdrive rubber dampner plus the assorted fastener here or there. Just ordered these! I should have a roller by the end of the month and will post pictures of the bike shortly.

New wheels and tires are also ready to be ordered. The rear wheel will be from one of my earlier KLR projects. This wheel is a 17"x4.25" black Excel built by Woody's Wheel Works in Denver, CO. I will be sending this wheel back to Woody next week to have a tubeless conversion done on it. The front wheel is a used KX450F wheel that I bought off eBay. It will also get a black Excel wheel and a tubeless conversion. A 19"x3.5" Excel will go on it. The hub will be powdercoated a matching flat black. The tires that I will be using on the Diesel KLR will be Metzler Tourance tubeless dualsport tires. My thought is a lower rolling resistance type tire and less unsprung weight because of the lack of tubes, will help the bike reach a higher topseed. The 140mm Tourance is the widest possible on the KLR. Handling should be great, even if the bike is somewhat slow due to a lower than normal topspeed. The mileage should be awesome. A spare set of stock KLR wheels will be available for off-road use.

It's slow going but things are finally starting to coming together.

SamM

Edit: I resized the pictures to fit better, posted a link to a video of the Winsun engine and added more information.

Video link:

[Weldangrind]

Can't wait Sam!

What are you going to do with the exhaust?

[SamM]

Weldandgrind,
Haven't decided yet. I'll probably either go with an inexpensive aftermarket muffler for the KLR or a muffler for a smaller bike. Maybe an HMF muffler for a DRZ. Whichever way I go the muffler will be in the stock KLR muffler location. I haven't really started looking yet. Too much else to figure out.

The muffler on the Winsun engine is located in the front and the outlet faces forward. This will be reversed and the pipe will go straight back into a stock type KLR system with the aftermarlet muffler. Also, the stock Winsun fuel tank will be removed from the engine.

The jackshaft parts aren't very expensive. I will also be ordering these parts and the Comet/Salsbury Series 500 CVT this month. Decided to use the 500 Driver and 500 Driven CVT parts which will get me a .81:1 overdrive ratio in the CVT transmission. The Driven unit comes in either a 3/4" or 1" shaft. The 3/4" looks to be the best choice. The final drive ratio will be worked out as I go. I'll make the best guess I can and then go from there.

SamM

[SamM]

WooHoo! My diesel engine arrives today. Paid for it last Friday, when I overnighted the Cashier's Check to A1biofuel.net Thursday morning. Mr. Hansen shipped the engine out to me Monday morning. It will arrive at my house today via UPS Freight.

The KLR frame needs modified in order for the engine to fit. The engine will be mounted as far forward as possible. Inch square tubing will be used for the engine cradle and the 3/4" jackshaft will mount behind the engine. I know that I have posted all of this before but I'm getting very excited about the project. I may even run out and get some diesel fuel and start the engine later today.

Stay tuned. It's going to start getting good now!

SamM

[SamM]

The Red 2008 KLR in the photo below in my signature, is the bike that I am converting into the Diesel KLR. It was the first '08 KLR that I owned. My wife bought this bike for me for Christmas Dec. 22, 2007.

The bike will use many 2007 KLR parts and will look more like the earlier KLR models. It will have completely custom front and rear suspensions on it.

Just a little background info.

SamM

[katoranger]

Sam, this is my favorite project so far. I wouldn't mind a similar setup in a street bike for commuting on.

Allen

[SamM]

katoranger,
The engine is here! We just unloaded it off the UPS truck. Wow, it's heavy. I think most of the weight is the crate though. They boxed it up nicely. It's raining right now or I'd uncrate the engine and test run it. Can't wait to hear it run. This is going to be a fun project. I'm really excited about getting started on it.

Hey, I must apologize! I didn't get your shock shipped today. I'll do it first thing in the morning. It's boxed and ready to go.

EDIT: just added a couple of pictures of the new diesel engine!

SamM

[katoranger]

Very nice. We will need video of it running on some veg.

Allen

[SamM]

No veggie oil. Bio-Diesel only! The first start will be on regular Low-Sulfur Diesel fuel unless I can find some bio-fuel in the next few days.

SamM

[katoranger]

Are you planning to brew your own at home eventually? I did alot of miles in the mercedes on veggie, but never tried any biodiesel.

Allen

[SamM]

Yes, I hope to make my own. A friends father owns a local diner. I also just recently bought a simple recipe for making it cheaply. No titrations. Mix and wash.

SamM

[SamM]

More pictures! I'll be starting the frame fabrication shortly. This gives you a good idea how the engine will fit in the frame.

SamM

[offroad1]

Sam,

What's the status of your project today?