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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 |
Here's a couple of quick pics. The new Trail Tech X2 headlight is raised and mounted solidly. A small windscreen will be added later. The new KTM Military mirrors are also on it. These fold down out of the way when going off-road.
She's starting to look sweet! SamM http://img46.imageshack.us/img46/5534/cimg3518.jpg http://img46.imageshack.us/img46/1497/cimg3519.jpg |
Thank you for your excellent reply, Sam. :) Your KLR keeps looking better, and better! Please keep posting the updates, and the superb photographs. :)
Spud :) |
I'm diggin' those mirrors Sam. 8) Do they vibrate much on the highway, or do they maintain position?
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Thanks Spud! Will do! :wink:
They vibrate all over the place Weldandgrind. I think it's mostly due to the Dunlop 606 tires. I'm doing new extreme-duty wheels for the bike later. Hopefully, the new wheels and Heidenau K60 tires will fix that. The 606's are very aggressive and work great off-road though. The Heidenau K60's will last much longer. Up to 10K miles and maybe more is possible. They have a harder compound and less aggressive dualsport tread. Both my project bikes will get the Heidenau K60 tires. Back to the mirrors. They are the same mirrors that KTM uses on the Military motorcycles that they make and sell to the Austrian Military. I purchased them from a gentleman in California. They are a little pricey at $30.95 each plus $12 shipping. I used these on my 2005 KTM Adventure S and my dualsported 2005 Yamaha TT-R250. I love them for off-road use. SamM |
Wow! That bike looks sinister! (in a good way of course) :) Really curious on the weight, please let us know when you get a chance to scale it.
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Here's the latest picture of the KLR. It's still not quite finished, as I am waiting on a few last minute parts to get it running. The 1/4" aluminum flat plate for my rear rack has just arrived. I'll have that on it shortly. There are a few last minute wiring issues to sort out and I'll be done with it. I'm iching to ride, it's been too long!
The new titanium muffler has arrived and I'll be fabbing a completely new lightweight exhaust from the engine back. The new exhaust will drop a bunch of weight off the bike. I'm also considering a Mikuni flatslide carb swap to increase the horsepower with the new exhaust. Thought you may want to see it! SamM http://img168.imageshack.us/img168/4271/cimg3694.jpg |
The bike looks great, Sam; thank you for the update! :) If you get it on the scales, please let us know how much weight it lost on your "diet." ;)
Spud :) |
Spud,
Actually, I'm still far from weighing it. My wheels are being stripped, so that I can send them out for a rebuild. I'm going with the 21/18" combination and the Nuetech TUbliss sealing system. This will drop 3lbs from each wheel. Woody's Wheel Works is doing them for me. Woody did my last set of wheels. We'll be sending them out this week. Finally have the extra coin to finish some things up. We ran it to a few problems with the wiring. It's been a real pain. We do have some really good plans for dropping more weight from the KLR. Nothing is being left untouched. Most of this new stuff and the engine work will have to wait for Winter. I just want to ride for now. The airbox is going away next Winter and I'll be converting it to use a Lithium-ion battery that is 7lbs lighter than the current AGM battery that's in it. I have also just purchased a 4lb Titanium muffler that is more than 10lbs lighter than the stock muffler. I expect to drop even more from the exhaust system with a new FMF header and a Hindle mid-pipe. The stock sidepanels will probably be going back onto the bike after I fab new mounts for them. Honestly, I'm getting tired of projects! :roll: Here's a recent picture of the bike with the new '07 radiator and fan. We stripped all the unused subframe and frame tabs from the bike. Over 6lbs was cut from it. I jst found another pile of stuff to cut off near the radiator overflow bottle. SamM http://img146.imageshack.us/img146/1748/cimg3625d.jpg |
I want to report that I have finally weighed my Lightened KLR and the bike comes in at: 345.2 lbs.
The bike was weighed with two different scales. It had a completely empty fuel tank, the stock muffler was removed and the new Titanium muffler was mounted on the bike using the rear muffler mount and bolt. The JNS skidplate was not on the bike either. Not sure which skidplate I will use on the final version yet. Either the Moose Racing or Happy-Trail. They seem to offer the best protection and lowest weight. This number will go up and down as I make changes to the bike to suit my use. The new number is a little higher than I had hoped for. I'm not really happy but I'm not discouraged either. I will keep cutting away at it, until I get the bike down where I want it. The next round of mods include: new handlebars, bar risers, a new headlight switch, new DR650 throttle, Motion Pro throttle cables, Moose Racing DR650 throttle tube, a Mikuni TM-40 carb swap, removal of stock airbox, K&N filter and pre-filter, swap to a lighter Li-ion battery, 5 gal IMS fuel tank, Rekluse auto-clutch, brake petal removal, choke cable removal, clutch cable removal, new Excel 21/18" wheels, Heidenau K60 tires, Neutech TUbliss wheels seals, radiator overflow bottle removal, stock cooling fan removal, and some more frame cutting. The new exhaust will be completed as soon as the Hindle midpipe arrives. The bike is also getting a new FMF Powerbomb header. I'd like to get it down in the 300 to 320lb range. After finally weighing it and checking the weight of some of the stock parts, I believe it can be done. I will be making a new smaller aluminum airbox and reattaching the stock '08 sidepanels. I'm not sure if it will ever be done but I'm riding the KLR everyday now and it's back on the road. I'm taking the bike on it's first trip tomorrow. SamM |
I'm glad to hear you are riding again, Sam! You've done a superb job, and pared a lot of weight off your KLR650. I am sure the bike is much more nimble, and it looks great! :)
Spud :) |
It sounds like you've built a single track machine. :D Please let us know how you like the Rekluse.
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I soooooo love the looks of that bike! :) Following your progress on 650 net as well. Awesome job!
Cheers! Stew |
Just want to report that I am still plugging away at my bike project. Many of the mods on my list have been done. Mostly the small stuff. The Vapor is on the bike, along with the new Spal cooling fan and the Moose Racing fatbars. I will be continuing the lightening process. This bike is pretty much going to stay as it is now, but a few changes will hopefully make it better. I'll need to keep this one as my daily driver and it's turned out to be great for commuting. Some suspension mods are in the works. Possibly a new rear shock and new front springs for sure. A new, bigger front brake may also be something that I want to do. The oversize 270mm Galfer wave rotor works fine but when I add hardbags and a little more weight, the front braking could become overwhelmed with the changes. I'm also looking to finally add the Rekluse auto-clutch this Winter. A smaller IMS fuel tank and Happy-Trail radiator protection will be on the bike soon. New SW-Motch EVO racks from Twisted Throttle are going on it with my Pelican hardbags. This is a better option than my very large drybag and cyclerack. If money works out, I'd also like to finally get my new 21/18" Excel wheels ordered and on it this Winter. One of my pictures shows the bike with a 950 windscreen added to the Trail Tech headlight. I've tilted it forward Rally style and it works great.
My new exhaust system is on the bike and I'll be changing the jetting this week to cure the VERY rich condition that I've been dealing with. I may keep the KLX needle but I'll be doing a few little carb tricks to improve fuel atomization. I'll report how those work. The carb also needs a new diaphram. The balancer adjuster still needs fixed on this one. Just never found time to do it. At 10,000 miles it's long overdue, so I'll get to that one in a week or so. Riding season is about over here. There's really no hurry as the weather is turning crappy. Hope everyone here is doing well! Take care! SamM Recent trip on BRP http://img823.imageshack.us/img823/3710/cimg3969.jpg New '01 GSXR1000 TI mufflerand Powerbomb header http://img163.imageshack.us/img163/829/cimg3962h.jpg |
Hey Sam!
Thanks for the update. I never thought of a Gixxer Power Bomb on a KLR, but I guess the KLR does have a relationship with Suzuki. Was the pipe a good fit at the head? You packed a lot of gear on your bike. Were you camping? What is BRP? Is that an old XR converted to DS next to your bike? |
Looking good!
Enjoy the BRP! I recognized it from the pic even before I read the subtitle! Bill. |
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http://www.virginia.org/brp/ I have driven Skyline Drive, from Front Royal, Virginia, to Charlottesville, Va; it's a beautiful ride. I'm sure the BRP is just as nice, or nicer. :) Spud :) |
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The only GSXR part is the 3.8lb Titanium muffler. The Powerbomb header is from FMF and is actually made for the KLR. Sorry, that probably wasn't clear. Yes, it fits perfectly. I did have to cut the inner fender to clearance it a little. If not it would melt. Yes, we were camping. I have my tent, sleeping pad, sleeping bag, a little food, wet weather gear and clothes for a week in the green drybag. The small yellow drybag has emergency items, spare parts and tools. The white bike to the left of mine is a 1999 Suzuki DR650. Chinariders member Pumpkin who works with me owns that bike. He posted here a few years back about his Lifan. He's moved on to the DR and is now looking to sell it and buy a new DL650 V-Strom next Spring. Great trip! The weather got us in the end and we made a run for home earlier than planned. We planned for 6 days but only lasted 4. Some of our group bailed on the third day and with just 3 of us left, the group dynamic was lost. We soldiered on but made a mad '600 mile' dash for home on Thursday. SamM |
Thank you for the update, Sam! :) Your bike looks great, especially the front end. I think the fender, 950 windscreen, and Trail Tech headlight really compliment each other! :D I forget; are you using the stock fender?
Spud :) |
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Beautiful ride. Nice work on that KLR. Skyline and BRP are on the plate for next year's Dragon Run...if I can talk the wife into it... :twisted: The Parkway runs right into the Dragon area on the "way home"... :wink: Bill R |
SpudRider,
The fender on my bike is from a 2008 Kawasaki 'Monster Energy' KX450F. You need to order the one for the Monster Energy version to get it in black. BillR, The BRP is great fun. The speedlimit is only 45mph but, IF you are careful you can push it pretty good. Most of the riding is very remote. You never know where a Ranger with pop up. We rode most of it on the way back at between 60 and 65mph. The best road was Rt. 250 from Waynesboro, VA back over the mountains into West Virginia. AWESOME road! Highly recommended! ------------------------------------------------------------------------------------- Many people don't realize that the Blue Ridge Parkway wasn't finished until 1987, I believe. This year is the 75th anniversary of the beginning of it's construction. The picture shows the Linn Cove viaduct. This was the last section of the Parkway to be finished. They needed bridge building technology to catch up before they could construct this bridge. This technology came from the Germans. Much of the autoban is built like this. SamM http://img139.imageshack.us/img139/7894/cimg4008.jpg |
Thanks for posting the beautiful photograph, and the information on your fender, Sam! :)
Spud :) |
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I really like it when the "squids" blow by me at warp speed...I just pick it up a bit and smile when I go by them while they have the "blue light special"... :wink: Bill R |
I really like the viaduct. I'd go back and forth on it a few times when riding that section of the BRP. As beautiful as it looks in that picture, you can't imagine how cool it is to be there.
I don't mind the speed limit so much, as the car/minivan or whatever in front of me. For me its not about the speed as much as the view, the experiance, and the freedom. Following a soccermom in a minivan causes me physical pain. |
Here's a teaser spyshot of my new 2008 KLRE650 in the build process. Thought you guys might like to see it. Still much to do.
SamM http://img840.imageshack.us/img840/6498/sklre2.jpg |
It looks good, Sam! :D Please don't tease us; show us more! ;)
Spud :) |
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