2008 Kawasaki KLR456 Diesel Motorcycle Project - Page 8

Jim · 06-20-2010, 08:22 PM

That's too bad to hear.

katoranger · 03-21-2011, 08:35 PM

Since SamM is back around lately we need an update.

SamM · 03-21-2011, 10:16 PM

Well, I still have all of the parts that I previously aquired for the Diesel KLR project. Nothing has been sold and the engine is in my storage unit. The Diesel KLR was put on hold for many reasons but I have recently considered getting back into that build. Today, a part that could only be used on the Diesel arrived. I'm not exactly sure why I bought the Aprilia leftside rear caliper bracket a few days ago. The only bike that I have, that it would work on is the Diesel KLR. So on some deep level, I guess I'm still thinking about it and buying parts for it. All I need to make it a roller is a KLR front wheel.

My other KLR (yes, I have two) is off getting a professional engine swap. The new engine is from a 2008 KLE650 (Versys). We are calling it a KLRE650. If I get back into the Diesel it won't be until the KLRE650 is done. The KLRE is being built in a topsecret lab halfway across the country from me. I have a small fortune tied up in it at this point. Not really! I don't want to have more than one project going on at same time. When I do that I spread the cash too thin and things get even slower. I can't afford to that.

So, the update is that IF I do decided to get back into the Diesel KLR456 project, it will have to be next Fall and Winter. My KLRE builder has offered to make the downtubes for the Diesel. I'll probably take him up on that.

SamM

SpudRider · 03-21-2011, 10:29 PM

Thanks for the update, Sam!

Spud

FastDoc · 03-21-2011, 11:36 PM

A KLRE would be the perfect tool for humilating BMWs. 8)

katoranger · 03-22-2011, 01:31 PM

Is the versys a twin?

FastDoc · 03-22-2011, 01:41 PM

650cc 4V 4 cam V-Twin. :P

katoranger · 03-22-2011, 01:47 PM

Sounds like fun.

david3921 · 03-22-2011, 04:32 PM

Hmmm, KLRE650, where have I heard that before? Oh yeah, here;

http://www.advrider.com/forums/showt...ghlight=versys

SamM · 03-22-2011, 05:07 PM

Repsolrider and I started our builds at roughly the same time. He owns a shop and has access to everything there. If you check that thread, you'll see that I have posted in it several times. My plan was to get the KLE engine to fit into a stock 2008 KLR650 frame. At this point, I don't think it's possible. The front engine tab that has the engine numbers stamped into it would need to be removed in order to fit the KLR frame. I'm not willing to do that as I may need to prove where I got the engine at some time.

After my build stalled, a friend that does engine conversions for a living contacted me about the bike. He offered to help and I took him up on it. After all he is a professional. He has other intentions and we are using my bike as the test mule. He plans to build one for himself after mine is completed. Basically, he's doing the engine conversion and getting it running for me. I will do the rest myself. The KLE650 engine is a game changer. It has 65hp, EFI and a 6-speed transmission. My engine, wiring harness, switch gear, ECU cables and misc parts cost me $1500 total. If you check my 2008 Ligntened KLR650 thread you'll see the donor bike. It weighs 345lbs and have 2008 KX450F USD forks. I did the lightening and the USD conversion myself, so I do have some skills!

I'll update the other thread with pictures of my 2008 KLRE650 after he sends them to me.

SamM

SamM · 05-11-2011, 04:06 PM

A couple of videos of the diesel KLR that I posted about at the beginning of this thread. The bike was sold to the current owner, Guy Compton back in January. He reports a 75mph topspeed. He also reports that the CVT slips a bit going uphill. My plan would be to use a bigger CVT to hopefully eliminate the slipping problem. My bike would use a rightside final drive instead of a stock KLR leftside final drive. We already have that worked out.

I'm thinking more and more about this build everyday!

SamM

AirJunky · 02-08-2012, 05:45 PM

Hey Sam,
Just wondering if this project has been dropped again or what.

Regarding your clutch & belt issues, maybe you can check with the custom golf cart crowd on CVT components. There are a number of shops around the country who build custom carts & use Comet clone clutches. Cartpartsplus.com is one who is very knowledgeable on this.

As for Guy's belt slipping problem, same resolution. The clutches can be rebuilt so they engage sooner/later. A short belt could be used, which will increase torque, especially when climbing hills.

Also the use of jack shafts with a CVT & chain drive is very common with custom carts using ATV running gear. Check out a site called buggiesgonewild.com & you will find a few of these projects done successfully..... and well documented.

I hope you will continue with this project. Wish I was closer. Would be a cool project to get into.

FastDoc · 02-08-2012, 08:25 PM

Welcome to the forum, AirJunky. You know a lot about this particular niche.

SamM · 02-08-2012, 08:27 PM

The project has not been dropped but it's on hold until my builder finishes my other project.

SamM

FastDoc · 02-08-2012, 08:44 PM

I just rode Roger's KLR about 20 miles in the dirt today including some single track and hill climbing and fell in love with the humble KLR all over again.

As I build experiance I can see the KLR being a good dirtbike.

I can't wait to see it as a diesel.

06-20-2010, 08:22 PM	#106
Jim Join Date: Mar 2007 Location: Abbotsford, BC, Canada Posts: 4,880	That's too bad to hear. __________________ "Be excellent to each other" "We are all human. Let's start to prove it!"
	0

03-21-2011, 08:35 PM	#107
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Since SamM is back around lately we need an update. __________________ You meet the nicest people on a Honda Clone.
	0

03-21-2011, 10:16 PM	#108
SamM Join Date: Feb 2007 Location: West Virginia Posts: 1,194	Well, I still have all of the parts that I previously aquired for the Diesel KLR project. Nothing has been sold and the engine is in my storage unit. The Diesel KLR was put on hold for many reasons but I have recently considered getting back into that build. Today, a part that could only be used on the Diesel arrived. I'm not exactly sure why I bought the Aprilia leftside rear caliper bracket a few days ago. The only bike that I have, that it would work on is the Diesel KLR. So on some deep level, I guess I'm still thinking about it and buying parts for it. All I need to make it a roller is a KLR front wheel. My other KLR (yes, I have two) is off getting a professional engine swap. The new engine is from a 2008 KLE650 (Versys). We are calling it a KLRE650. If I get back into the Diesel it won't be until the KLRE650 is done. The KLRE is being built in a topsecret lab halfway across the country from me. I have a small fortune tied up in it at this point. Not really! I don't want to have more than one project going on at same time. When I do that I spread the cash too thin and things get even slower. I can't afford to that. So, the update is that IF I do decided to get back into the Diesel KLR456 project, it will have to be next Fall and Winter. My KLRE builder has offered to make the downtubes for the Diesel. I'll probably take him up on that. SamM __________________ 2013 Jeep Wrangler Sahara MOAB 2005 BMW E53 X5 2011 Schutt Industries LTT-HC LQG trailer 2017 Coleman CT200U 1978 Yamaha SR500E 1979 Yamaha XS650 Special II
	0

03-21-2011, 10:29 PM	#109
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Thanks for the update, Sam! Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

03-21-2011, 11:36 PM	#110
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	A KLRE would be the perfect tool for humilating BMWs. 8) __________________ Happy to serve.
	0

03-22-2011, 01:31 PM	#111
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Is the versys a twin? __________________ You meet the nicest people on a Honda Clone.
	0

03-22-2011, 01:41 PM	#112
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	650cc 4V 4 cam V-Twin. :P __________________ Happy to serve.
	0

03-22-2011, 01:47 PM	#113
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Sounds like fun. __________________ You meet the nicest people on a Honda Clone.
	0

03-22-2011, 04:32 PM	#114
david3921 Join Date: Feb 2009 Location: Michigan Posts: 1,031	Hmmm, KLRE650, where have I heard that before? Oh yeah, here; http://www.advrider.com/forums/showt...ghlight=versys
	0

03-22-2011, 05:07 PM	#115
SamM Join Date: Feb 2007 Location: West Virginia Posts: 1,194	Repsolrider and I started our builds at roughly the same time. He owns a shop and has access to everything there. If you check that thread, you'll see that I have posted in it several times. My plan was to get the KLE engine to fit into a stock 2008 KLR650 frame. At this point, I don't think it's possible. The front engine tab that has the engine numbers stamped into it would need to be removed in order to fit the KLR frame. I'm not willing to do that as I may need to prove where I got the engine at some time. After my build stalled, a friend that does engine conversions for a living contacted me about the bike. He offered to help and I took him up on it. After all he is a professional. He has other intentions and we are using my bike as the test mule. He plans to build one for himself after mine is completed. Basically, he's doing the engine conversion and getting it running for me. I will do the rest myself. The KLE650 engine is a game changer. It has 65hp, EFI and a 6-speed transmission. My engine, wiring harness, switch gear, ECU cables and misc parts cost me $1500 total. If you check my 2008 Ligntened KLR650 thread you'll see the donor bike. It weighs 345lbs and have 2008 KX450F USD forks. I did the lightening and the USD conversion myself, so I do have some skills! I'll update the other thread with pictures of my 2008 KLRE650 after he sends them to me. SamM __________________ 2013 Jeep Wrangler Sahara MOAB 2005 BMW E53 X5 2011 Schutt Industries LTT-HC LQG trailer 2017 Coleman CT200U 1978 Yamaha SR500E 1979 Yamaha XS650 Special II
	0

05-11-2011, 04:06 PM	#116
SamM Join Date: Feb 2007 Location: West Virginia Posts: 1,194	A couple of videos of the diesel KLR that I posted about at the beginning of this thread. The bike was sold to the current owner, Guy Compton back in January. He reports a 75mph topspeed. He also reports that the CVT slips a bit going uphill. My plan would be to use a bigger CVT to hopefully eliminate the slipping problem. My bike would use a rightside final drive instead of a stock KLR leftside final drive. We already have that worked out. I'm thinking more and more about this build everyday! SamM __________________ 2013 Jeep Wrangler Sahara MOAB 2005 BMW E53 X5 2011 Schutt Industries LTT-HC LQG trailer 2017 Coleman CT200U 1978 Yamaha SR500E 1979 Yamaha XS650 Special II
	0

02-08-2012, 05:45 PM	#117
AirJunky Join Date: Feb 2012 Posts: 1	Hey Sam, Just wondering if this project has been dropped again or what. Regarding your clutch & belt issues, maybe you can check with the custom golf cart crowd on CVT components. There are a number of shops around the country who build custom carts & use Comet clone clutches. Cartpartsplus.com is one who is very knowledgeable on this. As for Guy's belt slipping problem, same resolution. The clutches can be rebuilt so they engage sooner/later. A short belt could be used, which will increase torque, especially when climbing hills. Also the use of jack shafts with a CVT & chain drive is very common with custom carts using ATV running gear. Check out a site called buggiesgonewild.com & you will find a few of these projects done successfully..... and well documented. I hope you will continue with this project. Wish I was closer. Would be a cool project to get into.
	0

02-08-2012, 08:25 PM	#118
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Welcome to the forum, AirJunky. You know a lot about this particular niche. __________________ Happy to serve.
	0

02-08-2012, 08:27 PM	#119
SamM Join Date: Feb 2007 Location: West Virginia Posts: 1,194	The project has not been dropped but it's on hold until my builder finishes my other project. SamM __________________ 2013 Jeep Wrangler Sahara MOAB 2005 BMW E53 X5 2011 Schutt Industries LTT-HC LQG trailer 2017 Coleman CT200U 1978 Yamaha SR500E 1979 Yamaha XS650 Special II
	0

02-08-2012, 08:44 PM	#120
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	I just rode Roger's KLR about 20 miles in the dirt today including some single track and hill climbing and fell in love with the humble KLR all over again. As I build experiance I can see the KLR being a good dirtbike. I can't wait to see it as a diesel. __________________ Happy to serve.
	0