My Turtle "Mia Fedora"

[Azhule]

While I wait on my China bike (still saving up the cash, probably for a Storm/BS250), I figure it's about time I started a thread for all my nonsense up in Northern CO, Southern WY, and Western NE :yay:

Current motorcycles: a 1995 Yamaha 100cc dirt bike with several thousands of hours of abuse and also my green "Turtle" or the "Franken-bike" a 1999 KLR 650 I bought used a few months back with only 11,000 miles on it, and I quickly built/fixed it with parts off of several different bikes/motorcycles, cars, and other things I find to make it better of course :p

The Turtle currently has parts off of Harley Davidson(s), Yamaha(s), Honda(s), a few other Kawasaki(s), a Ford car, and plenty of other stuff that actually belongs on it too :hehe:

http://www.chinariders.net/picture.php?albumid=126&pictureid=637

A bit neglected when I bought it, the 2nd owner purchased it one day about 2 years back... he rode it home the day he bought it... rode it to work or school the next day, then back home... then realized he didn't like it for whatever reason and it sat in his garage for almost 2 full years before he put it up on CL... it was up for an hour or 2 when I called and promptly purchased it for cheap :clap:

A few hours to a full day after owning it I had almost all of it's issues worked out:

At first it wouldn't hold an idle and would sometimes die in neutral... Pulled the spark plug, seen it was junk and tossed in the trash, I filled the spark plug hole/cylinder head area with Amsoil PowerFoam and installed a new Denso Iridium 5730 Spark Plug and waited 1.5 hours for the PowerFoam to do its cleaning magic.

While I waited, I cleaned up the electrics/connectors with Electrical/Contact Cleaner and sealed them with some new Dielectric Grease. I drilled out the cap covering the Idle/Air Adjustment screw and I set it to 1 and 3/4 turns out like the Kawasaki manual said to (was just over 2 turns out). I also cleaned the stock foam air filter, re-oiled it, and also put some "Complete Fuel System Cleaner" in the gas tank (Penray branded, contains PEA and other detergents/cleaners/emulsifiers/lubricants/etc.), sprayed some Power Foam in the Carb hole and waited a little bit longer.

After the 1.5 hour wait the bike fired right up and had tons of black/carbon filled smoke billowing out the exhaust for almost 3 full hours of riding :ohno:, I adjusted the idle screw a few times during the ride... had no problems the entire ride and the idle is still perfect today :tup:

Was getting 50 to 53 miles per gallon the entire time...

Well a week or so goes by and I started having problems again, everything smelled of gas (no visible fuel leaks, vapors galore), bike would just stall with no warning and would only start by doing random things... sometimes it would be as simple as opening the gas tank to vent air into it... other times it would be as complicated as re-setting all the "safety switches" AND messing with the battery... it was getting ridiculous to say the least >:(...

Turned out to be faulty California Emissions ("The Octopus") and the Vacuum operated Petcock :grr: $800 + tax and shipping to replace it... so I just removed it all and tossed it in a box labeled "More Kawasaki Trash" :lmao:

http://www.chinariders.net/picture.php?albumid=126&pictureid=652

I instead ordered an IMS 6.6 gallon gas tank (I kept getting fiberglass shards from the OE tank anyways...) and a Yamaha 660 Raptor Fuel Petcock (gravity operated) all for under $300... was going to take 2 weeks for the gas tank as the Army Green Natural/Translucent was a special order item...

http://www.chinariders.net/picture.php?albumid=126&pictureid=651

In the mean time I started looking over the "safety/annoyance kill switches"... all 3 of them had corrosion or rust build up one way or the other so I decided to just Remove/Bypass all that junk... I've been riding motorcycles for almost 26 or 27 years by now... not once have I needed those annoyances :crazy: half the time they leave me stranded when nothing is really wrong anyways :crazy:

No more problems to speak of with the bike after that... just ride for hours and hours with no issues... other then the Temp Swings on the engine :D another great design flaw from Kawasaki I would fix down the road (Thermobypass 2 upgrade)

Now that things were running good it was time to start really modding things... here's what I remember doing to it lol

ATC/ATO Fuses to replace those unreliable Glass Fuses Kawasaki uses.

http://www.chinariders.net/picture.php?albumid=126&pictureid=638

Battery Tender, 8 stage with a Desulfate phase.

Denso Coil on Plug upgrade to replace the expensive and unreliable Kawasaki Ignition Coil and Spark Plug Wire design... Found this Denso C.O.P. on eBay used for like $11 (each) shipped... I ordered a full kit off a trashed bike, 4 Denso C.O.P. and wire harness, was only $45 or $50 shipped for everything... and all I had to do was power to power, ground to ground and the bike fires right up... Kawasaki wants $480 + shipping and tax just for the Ignition Coil... and another arm or leg of your choice for the spark plug wire and boot...

http://www.chinariders.net/picture.php?albumid=126&pictureid=643

I still have 3 "C.O.P. kits" left if anyone wants to try and convert their China Moto over to a Coil on Pack Ignition setup ;) we can do it under half an hour while we eat/drink some gluten free food/beers :tup:

FunnelWeb Air Filter, made in Australia, a great filter with tons of surface area, only cost $28 (each) shipped to my house, got 2 of them for the price of 1 crappy K&N filter. Only problem is they don't have a "proper seal" like all of their other filters they make, might order me an UNI Ultra Seal Foam Filter for $12 and try them out.

http://www.chinariders.net/picture.php?albumid=126&pictureid=658

Harley Davidson Fuel/Air Emulsion Tube (CV-Performance brand) and 150 Main Jet... need to find a 140 or 145, bike running a little rich... if I can't find smaller than 150 it gives me a 'good' excuse to do a 685 to 705cc piston upgrade ;)

LED Lights for my Turn Signals and Brake Lights (forgot what brand and numbers I used, probably Sylvania or Philips branded)... saving about 80 watts of electricity after I swapped over to LEDs.

Low buck exhaust mod (cutting and grinding to flow exhaust gasses better)

KLX Needle upgrade

Megura Hydraulic Clutch so I can leave my "Hulk Smash" hands at home... I'm only 120lbs with little girly arms/hands after all :hi:

http://www.chinariders.net/picture.php?albumid=126&pictureid=653

Philips 194/T10 LED light bulbs to save a few watts and get more light in my RPM/MPH instrument gauge

http://www.chinariders.net/picture.php?albumid=126&pictureid=655

Secondary LED Brake Light (cheap junk from eBay... don't recommend at all)

Sunstar 17t front sprocket, dropped about 700 RPMs off my cruising speed

Thermobypass 2 upgrade

http://www.chinariders.net/picture.php?albumid=126&pictureid=639

"Vent Mods", I did the "T or Y Mod" to let air/fuel/water correctly go in and out of the carburetor

http://www.chinariders.net/picture.php?albumid=126&pictureid=656

And also a "PCV Mod" (positive crankcase ventilation mod), used a FRAM PCV valve off a Ford car, works great, no more water condensation/contamination in my oil

http://www.chinariders.net/picture.php?albumid=126&pictureid=657

OE Wheel Bearings are toast with no butter :ohno: I found grease, dirt, sand, moisture, and other crap stuffed in the wheel bearings... dealership wanted over $400 do replace the front and rear wheel... $120 + tax/shipping for the bearings and then the cost of labor on top of that... for about $125 I got a Tusk Wheel Bearing Removal kit and some All Balls Racing Wheel Bearings, swapped out the old ones in under 40 minutes :crazy:, I'm still wondering to this day why I was going to get charged for over 3 hours in shop labor for 35 to 40 minutes worth of work... and I have basic tools to do repairs with (other than the Tusk Bearing kit)... no fancy motorcycle lifts or anything... just a block of wood to prop the bike up lol

http://www.chinariders.net/picture.php?albumid=126&pictureid=645

http://www.chinariders.net/picture.php?albumid=126&pictureid=646

Sorry for the long first post in this thread, but you are now basically caught up on the last 6 or so months of making my Kawasaki a reliable 'Frenken-bike'.

[rojo_grande]

Nice work.

Have you done the Doo yet or the $.22 mod? Been think'n about doing the thermo-bob as well and will probably need to do the raptor petcock soon.

Rojo

[Azhule]

I actually just ordered the Idle Adjustment upgrade ("the Doo") from Rocky Mountain ATV... just did the order earlier this morning after I found my (small) Tax return was deposited :lol:

When you get the Raptor Petcock, make sure you spend the few extra $ and get an actual "Yamaha/OE" branded fuel petcock, know a few people who had problems with the "eBay/no name ones", look for part # 5LP245000100 (this one has the right sized fuel connection), that was what showed up on my receipt when I got the Raptor 660 Petcock ;) you might need to find out what all hoses/vents need to be blocked/bypassed/connected to make the bike run right again, it took me a few tries to get it right with my IMS gas tank :p

I skipped the 22 cent mod and just went with the KLX Needle and a Jet kit, I shortly dropped the Kawasaki Jets and Emulsion tube and went with a CV-Performance "Harley Davidson" Jets and Emulsion tube... have a few different Kawasaki pilot jets I'm going to try out to find out what I like best for jetting :shrug:

With the KLX Needle my bike seemed to run good on with the Needle on the 2nd Clip, with a 140 main jet (stock 40 pilot jet... never tried other pilot sizes), and 1 and 1/2 to 1 and 3/4 turns out with the Air/Idle Mix screw.

Still messing with the "Harley Davidson" jetting, don't remember if I ever installed the 150, or if it was on my "to order list"... :doh: just went and checked my box-o-parts I'm only finding part numbers for 160 for the lowest HD main jet :doh:

[FastDoc]

Nice work indeed.

The KLR is one of the best all around bikes EVER, and the Zombie Evasion Bike Of Choice in the Northwest. If a person could only have one bike (God forbid, I'd die in weeks) the KLR would be the right one.

[Azhule]

I was extremely lucky in finding this UNMODDED gem of a bike, other than it being a little abused from the "lack of use" over the last few years, it came with a box full of dealership maintenance that was done over the 11,xxx miles of previous ownership, oil changes every 800 or so miles, valves checked every 2,500 miles (but never needed done), etc. etc. :clap: I got all this for $1,300...

I could have got it for a lot less but I didn't feel like playing games and wanted this gem :D I have the ability to fix anything cheap (my labor is free and I have most tools I need) that's wrong with it, I'm almost done with the build and it will be fully modded and built to MY liking for well under $4,000, that includes the price of the bike, title/plate fees, and insurance for the first 2 years of me owning it (probably have another year to year and a half before I have enough for the front brake and suspension upgrades so I included that insurance and plates in the cost :yay:)...

Tried going to local dealerships (and a few other private sales) and they all wanted insane prices for OLD bikes, I didn't even ask for prices on the NEW(er) bikes... the one place I tried to pre-order a 2016 Suzuki DR650 from kept dinking me around on the delivery date (and wouldn't 'sell' me the one on the floor...) so I ended up getting my $ back and started modding the KLR 650 instead :lmao:

This 1999 KLR 650 was my first ever CL purchase, and I think I'm quitting CL while I'm ahead :hehe: the reason I named her "Mia Fedora", she showed up randomly in my life when I was looking for a cheap/used motorcycle, the owner was legit and didn't like to mess around (he had paper work ready, test rides, was friendly, etc.) and promptly disappeared after I got his plate back to him (didn't have the tools to remove it and he said to just "drop it off to me here when it's off the bike"...) :)

I can't wait for this weekend, should have that Rocky Mountain order by then, and I can finish up a few things on the bike (rear brakes, pilot jet, exhaust header) :yay:

:ohno: I forgot to add the special wrench and bolt I need to remove the parts and get back to the Doo... Oh well, gives me an excuse to order the front brake upgrades in a few weeks when my Bday rolls around :tup:

[Weldangrind]

Oooohh, I have so much to learn!


I have a baby KLR, and I'm wondering how much I can apply. Please explain (or point to a link) about the thermobypass mod.

[rojo_grande]

Here's a link to the thermo bob. http://watt-man.com/ I believe there is a KLR250 version. Check the info and articles/FAQ section.

Also available at rocky mountain atv but I believe only for KLR650.

$.22 mod is just a way to shim the stock needle. Add a couple #4 stainless washers under the needle and drill the hole in the slide a little. At least for the KLR650, it wakes it up a bit, better throttle response. KLX needle kit is also and option.

Rojo

[Azhule]

Thanks for helping out with the quick info rojo,

But yeah it's the Watt-Man Thermo-Bob 2.

http://shop.watt-man.com/Thermo-Bob-2-for-KLR250-ALL-MODEL-YEARS-TB2R.htm

And the articles http://www.watt-man.com/Information__Articles.html

Might be what you are looking for Weld ;) , I can explain more on the Denso C.O.P. if needed, but a few pics of the spark plug, wires, coil, boots, and anything in the surrounding area's will be needed as well (measurements help a bunch too lol) :)

I'm used to the other forum spamming links so I change a few words/names here and there to cut down on the spam/bandwidth on my threads lol

One of the better purchases I made in a while was the Watt-Man Thermo-Bob 2 and some Prestone "Prime AF3000" Antifreeze/Coolant (a silica free blend, perfect for my motorcycle and most cars I own).

The bike runs at the perfect temp every time I ride now :) only takes a short warm up period (5 or so minutes) and it never drops below the proper temps

[kohburn]

+ on the thermobob. I installed one on my versys and it helped with faster warm up and much more stable operating temps in cold weather.

[Weldangrind]

Thanks Guys! :D


Does anybody happen to know if there is a doohickey mod for the baby KLR?

[rojo_grande]

No doohickey on the KLR250. Plus the KLR250 has screw valve adjusters vs. bucket and shims on the KLR650.

[Weldangrind]

Here's where I need to be schooled.


I'm pretty sure that the doohickey mod refers to the tension spring on the KLR650 counterbalance, correct?


The baby KLR has a similar tensioner, so I only presumed that it might need a similar mod.

[Azhule]

I would also need to a lot of reading on the KLR 250 (I did some when I was looking at buying road bikes, but didn't do much reading up on the 250cc bikes, wanted a 400cc minimum), the little research/threads on the KLR 250 I read of NO problems mechanically with the engine/transmission/tension/counterbalance systems (for years of abuse and several thousands of miles), always the general complaint was about the suspension, the gas tank (not enough gallons), and a cruddy seat :)

Anyways, feel free to chat away, it's boring up here in the middle of nowhere Northern CO/Southern WY after all :)

[SpudRider]

I bet you don't live far from Cabela's main store in Sidney, Nebraska.

[Azhule]

About a 2 hour ride with the current traffic Spud, why did you need something from there ? :lol:

I think I can get there and back home with a few gallons to spare in my IMS 6.6 gallon gas tank :lmao:

[rojo_grande]

Agree with Azhule. Looked at the KLR250 briefly for Marzhere but the seat height was going to be a problem for her. The KLR250 by all accounts seems relatively bulletproof.

My limited understanding is that the KLR 250 and 650 engines don't share much of the same engineering. The KLR 650 issue is both the balancer adjuster lever (doohickey) and spring are prone to failure. Not so for the KLR 250. However, both the 250 and 650 suffer from poor suspension and bad seats.

[Azhule]

Well I had a nice little scare with the electrics... I went out to do a few quick things to the bike before my shipment of parts arrive in the next few days... I ended up deciding to do my monthly "do all my lights work" check while I was there... I put the key in the bike and turn it over to "ON"... nothing comes on but the Neutral Light and High Beam Indicator... no headlight, dash lights, or tale/brake lights was actually on...

So I try pressing the brake peddle as a test and the rear lights go off like it should... along with my License Plate Lights, they decided it's time to work when I press the brakes now :shrug:

WTF 'Mia'...

Dinner is going to be done in 3 minutes and you do all this crap to me???

Well I stopped the b***hin and just got to it... I pull all the plastics, the seat, and the gas tank and start messing with all the wires I might have "recently disturbed" while I was doing the Thermo-bob install (without removing the gas tank, seat, or plastics I might add :lol:), and also to check my ATC/ATO fuses, the battery, and my Denso C.O.P. wires... everything was fine... dinner was done almost 8 minutes ago... I was getting hungry and vary pissy...

Wait a second...

I glance over and notice a connector not full seated... I completely forgot to fully re-connect the main connector for the lights last time I was messing around in there... it popped itself loose sometime the other day when I was out on my ~20 mile ride :)

[SpudRider]

Of course, I always need something from Cabela's. ;)

I frequently ride I-80 across Wyoming and Nebraska when I travel back east. Whenever I travel that direction, I always stop at Cabela's flagship store in Sidney. :)

[FastDoc]

If a man can't find something that he wants at Cabela's, he's a communist and should leave the country.

[Azhule]

Next time you ride through Spud let me know, I'm right near those cross roads (Cheyenne/Nebraska I80 area), we can see about finding a place for food (its hard with food allergies) or maybe we can find a nice road to ride on your way.

More parts came in the mail today so I got some mods done to the bike today :lol: got my turn signals working (old flasher was poo for lights in general but never built for LEDs), all the Flasher did was "solid on turn signals" (even with the old school bulbs) doesn't flash anymore... a "Tridon Novita" flasher I picked up from Advance Auto seems to be working so far.

I also tossed the old Fan relay in the trash... I upgraded to a relay that is basically built for constant use (30 amp horn/light/audio relay) not one built to burn out when temps get above 80F outside and you get stuck in traffic or going slow off road for a few hours :)

http://chinariders.net/picture.php?albumid=126&pictureid=662

Took apart the rear wheel for some much needed brake work and upgrades :D put on a new Tusk Rotor, Galfer Green Brake Pads, and of course a Stainless Steel Brake Line with new Mag 1 DOT 4 Brake Fluid :yay: braking is 100 million times better from when I bought it... I also rebuilt the brake master cylinder a week or so back... braking and pedal feel was a little better after the master cylinder rebuild but still really spongy and poo overall (old brake line bulging and flexing I'm guessing).

http://chinariders.net/picture.php?albumid=126&pictureid=665

http://chinariders.net/picture.php?albumid=126&pictureid=664

Replaced the Air Cutoff Valve/Diaphragm dealy in/on the side of the carburetor :clap: and also have a new pilot jet to try out if I feel like digging in the carb any more... Kawasaki recommends a few different pilot jets at my altitude and mods done to the bike :)

Also got the Eagle Mike "Doo" and Torsion Spring upgrade (and a new set of gaskets) in the mail today. I'm still waiting on the rest of my order, mainly a new exhaust, but it should be here sometime today or tomorrow.

New exhaust arrived and installed :tup: I like it, wife said it sounds like a helicopter :p Didn't get a chance to go for a ride yet, just a test start to check for leaks :D

http://chinariders.net/picture.php?albumid=126&pictureid=663

[SpudRider]

If a man can't find something that he wants at Cabela's, he's a communist and should leave the country.

That's a double amen, Brother. :tup:

[Tranberg]

You could also put Ecotrons EFI on the KLR650

https://www.youtube.com/watch?v=4dJVPgZUgdk

[Azhule]

Found Ecotron a while back when I was looking at the DR650 :) don't know if I would spend the $ on a Ecotron system to fuel inject it... I probably would end up take parts off random bikes and do a MicroSquirt ECU/EFI build :D

But to tell you the truth it will be a while before this bike gets any more upgrades like that again... did the maths last night and I'm already pushin over $4k in parts, specialty tools, motorcycle gear, and the cost of the KLR650... and I still have the front brakes, forks/springs/suspension, and a few more OE parts and after market Camshafts when I replace the "Doo" too... going to easily add another grand for all that too :hehe:

[Azhule]

Had a fun little ride with the new exhaust parts installed and 142 main jet, great time but something was still a little off... it has plenty more power than the stock exhaust with a properly tuned carb... it just didn't feel/sound/smell right when riding/testing things... well I got home after a nice ride to the store and I decided to remove the air filter cover as a starting diagnosis point... ahhh, much better when it can breath both in and out at a mile high :)

The other week after I installed the 17t front sprocket I went out for a ride and had to battle 40+mph winds, the bike was full throttle and maxed out in power at 60 - 65mph on the roads/hills/winds I was dealing with... well with the new exhaust and about the same amount of winds/hills/roads/temp on my ride today (first carb tune after exhaust mod), and I am able to just cruise around now and still have plenty of throttle left to accelerate up to and past 75+ (indicated speed, no GPS today on my ride :ohno: ), well worth the $ spent :tup:

I followed the Mrs. to the local Bulk Box store and home, for some reason she kept trying to race a bit on the way home lol, I think she wants to hear that lovely exhaust tone we just upgraded to, but she denies even racing up to speed (sooo, you didn't blip the gas pedal a few times at just before the light turned green? cause you promptly took off like a rocket making me chase after you ? :hehe: I know I have a helmet and earplugs in but I can still hear a car next to me rev at the red light :hehe: )

[Azhule]

What a nice day for a ride :yay: anyone else get one in? I made sure to get one in today as it's my Bday :yay:

Got just over an hour on the bike and probably 40 or so (s)miles just putsin around on whatever road I fancied :lol:

Hope everyone is doing well :tup:

[BlackBike]

If a man can't find something that he wants at Cabela's, he's a communist and should leave the country.

Vote for Bernie :lmao:

[Weldangrind]

What a nice day for a ride :yay: anyone else get one in? I made sure to get one in today as it's my Bday :yay:

Got just over an hour on the bike and probably 40 or so (s)miles just putsin around on whatever road I fancied :lol:

Hope everyone is doing well :tup:

Happy birthday! That's a terrific way to celebrate.

[FastDoc]

Happy Birthday!

Ride on!

[Azhule]

Huh... and here I said a few posts ago I probably wouldn't spend the $ on a fuel injection set up on my motorcycle (at least any time soon)...

Well I guess the Mrs. is tired of me and the surrounding area smelling like gasoline every time I have to mess with the carb/jets for tuning things...

So I told her "For a one time fee of ~$600" we could fuel inject the KLR with a 42mm throttle body and change fuel settings via laptop and I would never reek of fuel again...

Her response... "Well then... we will just have to save up and see about getting a discount when we order 2 kits..." :lmao:

One for my Kawasaki KLR 650 and a smaller throttle body kit for her 'WILL 200' China Bike we are going to order soon :tup: (the smaller kit goes for under $300 if I remember right).

What fun :yay:! Going to be a sweet 'winter project' Fuel Injecting the KLR 650 and the 'WILL 200', I wonder what kind of power/fuel economy I can squeeze out of them without taking it into a professional tuning shop :D

[SeerAtlas]

I've got a couple of KLRs and though great bikes, they are a real handful on the dirt side of the dual sport equation. Depending on what you've got loaded, north of 430 lbs is a beeatch to muscle around or try to lift if it happens to go down on the low side of a trail and that's assuming you're still in tip top -one piece shape after your unexpected dismount!
Unless you are a VERY strong guy or only ride the singletrack boonies with lots of friends, I find Much more peace of mind when solo exploring on my Hawk.

There is a reason all the you tube vids showing the KLR/BMW/KTM types out and about in the boonies are ALL traveling in packs.:)
CAN'T WAIT FOR THE TT250's!!!!!:}

[Azhule]

I personally love my 'heavy' 1999 KLR 650, sure I put a bunch of $ into it but it has yet to leave me 'permanently' stranded anywhere, the few times she did randomly have issues it was a 5 minute :hmm: head scratching fix to get back home, then fully fix the issue for the next rides... and I was lucky to get all those bugs worked a few rides into owning the bike :)

I'm fairly small at only 120lbs but I still have plenty of strength/technique/leverage to easily lift the bike off the ground (26+ years of "Karate" experience/training also coming into use)...

It also helps that I started gutting weight off the bike as soon as I got it, so far I have a box full of heavy/useless crap that I have removed and it is well over 35lbs of crap last I weighed it and I just dropped a little more weight from the FMF Header and LEXX exhaust upgrade (still have the old heavy battery to replace too and that will shave several more lbs of weight).

Sure I added a little weight too here and there, but no way it's more than a few (2) lbs so far with the Fork Brace and Thermo Bob 2 kit, and I will add another few lbs (4 or 5?) when I upgrade to Fuel Injection, but I should still be able to lift it no problems (unless I'm extremely tired of course :) ) it will still be lighter than it was stock when I wanted to power lift it a few times just to see if I could on my own "just in case" :lol: .

I have been riding different bikes on the dirt for 26 or more years now (I usually rode my 100cc Yamaha, and started on a PW50 a few months before I turned 4yrs old), but I haven't really had much issues with the hefty KLR off road. After I installed the Eagle Mike Fork Brace and new Wheel Bearings I have no "wash out" issues and I can just haul ace off road now... and I still need to save up to upgrade/rebuild the suspension :D

Still really lucky I haven't been down on or off the road, just dropping the bike on purpose to lift up a few times :)

Thanks for stopping by everyone :tup:

[SeerAtlas]

whoa!
I thought the 120 was a missprint! you have my serious respect. just as a matter of reference, i am about 250 and 6'3 and i too can lift it up, and i do occasionally singletrack it But i do it with extreme caution which takes a lot of concentration, which by and large detracts from the joy of the ride.


I am by nature exceedingly careful when i know that whatever happens the only one available to save my azz is going to be ME. When i was a much younger and less cautious man, on the directions of a scheming young Austrian kid (who no doubt hated italians (long story, bike had italian plates) I ended up on the wrong road in the alps, caught in a white out blizzard and had to clear my way through about 2 feet of snow some 40 ft off the road into a tiny hay shed where i rode out the storm for three days in the hay in the company of a comically fearless mouse who i named "hamlet". we literally "broke bread" together. :}
but all of that was on a ducati that was inches lower than my KLRS.

[BlackBike]

Wow azh, pretty impressive for that 650 . I thought the same as seeratlas as I read. With your expierence, I'm sure you just skip those lay over situations in the first place (aka thinking man's rider). I'm a newb so i am drinking this all in.

[Azhule]

Wow azh, pretty impressive for that 650.

:lmao: Thanks everyone, if I had a choice I would have gladly got a DR650, DRZ400 (or the 300+), XR650L, KLX400 (or the 300+), or any number of other bikes in the 400 - 650cc range I looked at that are lighter and just as "good/bad" on and off road :lol:... but those bikes/sellers all came with a premium cost for the same 5 to 20+ year old beat up junk, all showing up on CL and 'local' ads...

Then one day I seen the ad for a completely stock, never dropped or farkled 1999 KLR 650 with only 11,xxx miles, checked it out later that day after the guy got off work, then met and purchased it the next day at the bank for CHEAP! Guy told me he had it for 1.5 to 2 years and only rode it 3 times total, the first owner put all the mileage on the bike and it was all road miles, was always garaged too :hehe:

But like I said, if any of those other bikes I was looking at would have sold for what they were actually worth I would have gladly ended up with a different bike (those bikes are no where close to $2,500 - $5,000+ "FIRM" for a used and beat to sh* bike... no matter what used crap you add to the deal...)

This ol KLR 650 was dirt cheap to buy... it has been a little expensive to refurbish to my liking, but I will end up with a "Better than new 2016 KLR 650" for $2,000 (stock 2016 KLR) to $5,000+ less (modded 2016 KLR), and my old '99 will (soon) have FI, the SV650 brake caliper mod, and an upgraded suspension to boot :D

[SeerAtlas]

actually, you've done a better deal than you think. the pre 2008 klrs are (in mho) better dirt bikes than the 2nd gen bikes. targeted by Kawa as entry Adventure bikes. Longer travel forks , less weight, no fairing,etc, when u r done w your build, I think you will b more than pleased

on the net's KLR650 site are a bunch of gen 1 experts who (again imho) know more about those bikes than the Kawa engineers themselves.

In any event, fix that subframe problem, and strengthen those footpeg mounts and all will b well.

I Can offer you personal testimonials about the progressive rate fork springs, the chassis lowering dog links, the comfort of the 2014.5 new edition saddle,( find someone who just HAD to have a custom seat and wrangle for his stock one, And there is a san diego group of real life experts who will rebuild and custom spring your rear shock to match your body weight and riding style. HHHHUUUUGGGE difference to quote the Donald:) and they are a fraction of the cost of the commercial shock guys.
again gluck. and check youtube for klr raceing. great video.

[Azhule]

Well I just placed the initial order for a 42mm Fuel Injection Kit... waiting for the supplier to fix the price so I can actually pay and complete the order for the right kit (they had the price for the 100 - 250cc engines/fuel injection kit listed, was told to add the item with 42mm specifications in the notes, then check out but not to pay, they would fix the price, and then I pay/they ship)

If all goes well my KLR 650 will be fuel injected in a few weeks time :) can't wait, no choke cold starts at any temp/altitude is going to be awesome!!!

[BlackBike]

Will be tuned in for that one for sure .

[Azhule]

I will be sure to take plenty of pics and try to log any other info of the process as I go ;)

[BlackBike]

Auto idle control, sweeeeet. Such decisions as where to drill for the O2 sensor and welding the bung nut for it... good stuff.

[Azhule]

Such decisions as where to drill for the O2 sensor and welding the bung nut for it... good stuff.

O2 sensor needs to be placed 6 to 10 inches from the exhaust port to help with initial warm up, and it also needs to be at a 1 to 15 degree angle to keep condensation to a minimum according to the installation guide :tup:

Price was adjusted earlier this morning and I just paid for the kit, should take a few days to process then ship, and another week or 2 to receive it from the supplier (Ecotrons supplier from China :p , I'm saving $230 by going direct to the maker :p)

[SeerAtlas]

can't remember if you had upgraded your battery yet but i sure would make sure its always in near perfect condition. assuming your new injection is an electric one. usally dead battery means dead fuel injection, ergo the carb for the apocalypse ready klr.

[Azhule]

Takes 4.5 amps and about 70w to run the EFI set up according to the install pdf, the KLR 650 should have plenty of juice as I dropped a lot of watts when I upgraded to LEDs :) , and I still have the stator and rect. I could upgrade and that would give another 100 or 120w if I remember right ;) .

I still haven't upgraded the battery yet, but I need to soon*... smelling of fuel the other day got me a Fuel Injection Kit... and that took all my monies away from my "lighter/sealed battery fund" :lmao:

I'm thinking about getting a nice/inexpensive AGM battery now that I'm going EFI, it will still save a few lbs over my original battery (its over 12lbs!) and I would have a slight warning of the battery losing juice, those Li Ion batteries can just cut out with no warning from what I read... but I have no experience myself with Li Ion batteries in any kind of Automotive so :shrug:

I really don't think a Lithium Ion battery would be the best choice with the old (stock charging system) 1st gen KLR 650, with EFI it will be a higher watt usage/lower watt stator charging system that I currently have... if the Li Ion battery dies on the road (if I left the lights on with the bike off) I have no way to get it running any time soon. Maybe if/when I upgrade the stator/rect. I will get a really light Shorai battery :)

*From what I have learned about the Gen 1 KLR 650 charging systems and any 'non-sealed battery' will cause the battery to boil off water/acid/electrolytes, it constantly pumps too many amps back into the battery heating it up causing the old batteries (the water/acid) to boil :grr: yet another wonderful design from those genius manufacturers at Kawasaki :grr:

In theory a Lithium Ion Battery would be the perfect choice and any "Sealed" (AGM or GEL) Battery is also a great choice and they are also about 1/2 or less in cost :hehe:

[Azhule]

Finally decided that an "AEM 30-4110 UEGO Controller" (wideband O2 sensor and gauge) will also be ordered for the project :) have to make sure my motorcycle gets properly tuned after all :clap:

Oh how I despise waiting for things :ohno: it's going to be a long couple of weeks before my EFI kit even gets here... that's what I get for wanting to save $230 over ordering from the US supplier ("Ecotrons") :p

[BlackBike]

[QUOTE=Azhule;206869]Takes 4.5 amps and about 70w to run the EFI set up according to the install pdf, the KLR 650 should have plenty of juice as I dropped a lot of watts when I upgraded to LEDs :) , and I still have the stator and rect. I could upgrade and that would give another 100 or 120w if I remember right ............

I was eventually going to shop a led headlight for lower amp draw and I think it adds to more "high tech" look.

I just realized there are a ton of post on this thread before I chimed in I will have to go check them out. Kind of new to this thread and post thing this is the first time I have actually ever joined 1 and am amazed how much information there is To be learned.

[Azhule]

I was eventually going to shop a led headlight for lower amp draw and I think it adds to more "high tech" look.

I went with a 35w VVME BiXenon HID Kit for the Headlight, not a LED setup btw, I don't think I mentioned that anywhere in my posts :hmm: (sorry :hehe:)

I got a kit when it was on sale for like $48, but the price isn't that much more right now they are $54 including a relay kit (got one from the seller below) :tup:

http://www.ebay.com/itm/35W-VVME-AC-HID-kit-bi-xenon-H4-H13-9004-9007-9008-9003-/201461273443?hash=item2ee8071363:g:iBMAAOSwv0tVWYO Y

I don't know what kind/size of light or if you need both High and Low beam, I needed the BiXenon (both High and Low), installation was easy enough... I didn't even bother taking pics of anything it was that simple :clap:

Can't tell you on how long the VVME Kits last, but my friend sold me on them after he told me of his working for over 4+ years (mine is not even a few weeks/a month old).

[BlackBike]

Many thanks azh, headlight upgrade for future mod.

You should start new thread to showcase the efi, major project !

[Azhule]

Anyone ever get stopped by an elderly lady and have a random chat about "How good your motorcycle looks"?

Well as I was leaving a place I was about to put my helmet on, this lady who just walked in said;

"So that must be your bike out front".

Quickly remembering my manners I say...

Azh- "Yes ma'am it is".

"Did you build it to looks like that or was it made/bought like that"

Azh- "No ma'am not really, the only major thing I changed would be the gas tank, the one from the factory was always giving me fiberglass shavings" (I'm not about to tell her all the changes I made to the bike :) )

"Well I like it! It looks really good, I don't think I have ever seen one that looks like it"

Azh- "Thank you ma'am, I've been trying my best to take care of it and refurbish/rebuild it"

"I probably taken enough of your time already, you ride safe out there dear, and please remember 'Your invisible' on that thing"!

:wtf:

I couldn't believe it, this sweet ol' lady actually understood how us bikers live our rides... "we're invisible"!

I thanked her for being part of the small number of people who make it a little safer to be out and ride on the road! :tup: I wanted to give her a big bear hug before I left, but decided it was time to just

:thanks:

and leave, my bike agreed it started with out any choke and she took off like a bandit :lol:

[Azhule]

Many thanks azh, headlight upgrade for future mod.

Oh before I forget, be careful when doing this upgrade, the HID lights can run hotter than most headlights and have been known to sometimes melt the clear plastic lenses (or other cheap plastics) if they are too close to each other.

I didn't have to worry as my headlight housing is basically all glass and metal from what I remember :lmao:

So please do be careful if you get any HID Headlight kit.

:tup:

[BlackBike]

Oh before I forget, be careful when doing this upgrade, the HID lights can run hotter than most headlights and have been known to sometimes melt the clear plastic lenses (or other cheap plastics) if they are too close to each other.

I didn't have to worry as my headlight housing is basically all glass and metal from what I remember :lmao:

So please do be careful if you get any HID Headlight kit.

:tup:

I'm waiting for the last piece of the puzzle to come on the brown truck (first simple mod). Will post.

[Azhule]

Fork Seals have been replaced

https://www.youtube.com/watch?v=pj76ku5sxvE

I still haven't gone for a ride as I just finished a few min ago* and probably wont get out for the next few days, but the Mrs. said I can also get some upgraded springs while I was busy rebuilding everything :yay: so on order is a set of Progressive Springs :clap:

Can't wait to see the difference it makes actually having oil in both the forks (the left fork started draining out shortly after I bought the bike :ohno:)... and then again the difference it makes with some nice springs and some heavier Fork Oil :tup:

*In all of the Youtube videos you will notice the seals pop quickly... well I pumped the fork up with 90 or 100 psi and it didn't pop... so I left it for a few hours and checked on it... still didn't pop... so I fell asleep for a bit... woke up and couldn't get back to sleep figured I would check on the seals.

As I was walking up to the forks to check them I hear "BOOOOM!!! Hiiissssssss" :hehe: they FINALLY popped and I almost needed a change of pants too :hehe:

It was as easy Youtube said it would be... just not as quick... this time it was 4 or so hours with 90 or 100 psi in the fork :p

[Azhule]

>:( Well after 5 or 6 days of the run-a-round I finally decided to cancel my EFI order... first they told me 42mm TB was the one I needed, and it's $599 shipped, we have it in stock and it's the supply Ecotrons normally gets for their DR650 kits... so I order it... well 2.5 days go by and I get an email

"Hi, I talked to Ecotrons and 45mm TB is what you need for your Kawasaki KLR650/DR650, 45mm is the DR650 std kit, please measure and see if it fits"...

Soooo I email Ecotrons to find out what I need... and they told me 40mm or 42mm TB with a 248g/min injector is what I needed and don't know why the supplier said 45mm...

Soooo I email the China Supplier... "Please send the 42mm TB with 248g/min injector kit like we originally agreed on..."

And over the next few days I get several run-a-round emails... long story short... they don't even make or sell the 42mm Throttle Body Kit anymore, even though I was told (several times, by both companies) that is what I needed and they have it in stock and ready to ship... well they don't have it... or make it anymore for that matter...

Nothing but lies all around from BOTH Ecotrons AND their China supplier... I personally wouldn't recommend either company... wasted just shy of 6 days of my time and they still have my $599 on hold... might have to get the CC company involved to get my cash back >:(

Rant over :grr:

[Azhule]

BS200GY-9 aka DB-03-200 aka 'WILL' 200 was ordered earlier today :D :yay:

Can't wait to get the Mrs. on her first motorcycle.

Her picks on color options:
1st - Black
2nd - Orange

Ordered from 360powersports who claims they keep updated and current stock :hmm: but I don't know how that is when they list several color options in stock but only had "2 Bikes" in stock when I ordered (now only "1" is left in stock but the same 3 color options are still available :hmm:)

Either way I hope it is actually in stock what ever color actually shows, as it's the only bike that 'should' fit the Mrs. (under 30inch seat height) and for just under $1,300 for a 'new' motorcycle we had little to lose after all :clap:

And now the waiting begins :lol:

*PS* Thanks to someone on this site for posting a coupon code, it was still active when I made the order "save25" gave me $25 off my order :thanks:

[BlackBike]

Fight is on for the mso. I just got word this afternoon that my mso will be here next wednesday. I ordered on Feb 1st. Good luck getting yours sooner seeing how there are already lieing about the " in Stock" business.

[Azhule]

Looks like the fight is on for the bike too... :ohno: :p :lol:...

Got an email about being able to ship me a RPS HAWK... Uummmm... No?

So I called and talked to a nice lady who I could barely understand, my kiddo was going crazy next to me and I already have a hard time understanding most folks with any kind of accent (my good friend from Peach Tree comes to mind), she quickly and nicely passed the phone off to the guy who emailed me.

He said they "have plenty of RPS HAWKs ready to ship me 'today', it's more powerful (meh barely more in HP), in the color you want and the same price, the ROKETA DB-03 we have in orange on our floor but would still have to order one for you"... did anyone else catch that :hehe: they have to order one direct from ROKETA :hehe:

I told him the seat height was the issue, not the power, price, or colors, it was why we researched, picked, and purchased the "ROKETA" (as he called it). The seat heights I have been told from REAL LIFE OWNERS of the bikes have reported just shy of 29 to 30 inches for the "ROKETA", and it has usually been 34 to 35 inches for the RPS HAWK, that is upwards of 6 inches too tall for the Mrs... it's her first bike and she is timid to riding after all, we want her to be comfortable and be flat footed at all times :tup:

He told me he would measure some of the HAWKs and the "ROKETA" he has assembled on the showroom floor (the "2 orange" in stock btw) and send me an email to confirm the seat heights... either way I will probably be getting the "ROKETA" when all is said and done.

So far, I'm not complaining, his Show Room Stock is accurate and displayed online, when I called someone answered within the first 2 rings, they are nice, quick, and courteous, tried to give me a 'bigger cc' motorcycle for the same price that he could get me ASAP, understood my wanting of the 'smaller cc' motorcycle and would find out more on it ASAP (he will call or email within the next 2 hours).

No real problems at all (yet) :clap:

[BlackBike]

Post the Url for the will200cc from the retailer:thanks:

[Azhule]

Post the Url for the will200cc from the retailer:thanks:

I gladly will post the links, but first I want to make sure I actually get what I ordered... I would hate for others to follow any links/purchases I post, make an order, and be out any amount of $$... let alone the nice sized chunk of $1,300 :tdown:

It shouldn't take more than a week or 2 to receive the bike and MSO, according to who I talked to, the MSO will arrive 2 or 3 days after the Motorcycle... because I chose "Standard 2 or 3 day processing"...

But I will shoot you a PM BlackBike (in case you miss any updates here) along with a post on this thread for everyone.

[BlackBike]

I hope you get the smaller bike, you get what you wanted. I am always very wary of a Salesman

[Azhule]

Are the problems starting already? Possibly...

Well after 3 business days (3rd day processing), I get another email...

"Please call me at 'xxx' we do have this bike already assembled can I ship that one we have to add on a pallet also out web site did not charge the shipping cost if you can take our display model brand new I can eat the shipping cost let me know thank you. This is a orange color !!"

...

Sooo, now they don't want to ship me a motorcycle in a crate, they want to (for some reason) "eat the cost" of BOTH the shipping fees AND the assembling fees to get me a "floor model"... that has been assembled by who knows... that has been sitting on the floor collecting Texas Dust for who knows how long...

Well... I end up calling the number I was given... it ends up ringing for 30 seconds and I get a voice mail... so I call the 360PS store number... a lady I could barely understand picks up the phone in under a ring...

Long story short... "Manny" is the only one who can help me... but he is not there... the only way to contact him is by email... I try to tell her I was told to call and talk to him in person... "Yhus email him, he not in store at moment"...

So I call "Manny"s cell phone again... this time he picks up in under a ring and sounds rushed and a little pissy... all I get from him is "I'm not at office, I can't help you now, send email me so I email you when I get back to shop."... so why the hell did you tell me to call you... AND why did you also give me your cell phone number to call "so we can get this taken care of ASAP"...

Soooo, I email him... "Send me a crate with an unassembled Black or Orange Roketa DB-03-200 like I originally ordered and we agreed on during our first phone call/emails"

AAAAAAAAHHHHHHHHHHH!!!!!!! Just my lucky lately... everyone is quick to take my $ but doesn't want to ship the goods they claim to have in stock... maybe it's time to look for used Jap bikes again :p

[Azhule]

Started a new thread for my China Bike (here) (http://www.chinariders.net/showthread.php?t=16168).

BS200GY-9 aka "WILL 200" has been shipped.

Follow the thread in the "China Dual Sports" section for any more info on that ;)

[Azhule]

It's about time I get the KLR 650 back on the road (just before first expected to snow of the year :p )... I'm getting a Shinko 705 rear tire tomorrow and I should be able to ride my trusty KLR again :yay:

Figured while I had the Kiwi apart for the "Eagle Mike Doo Upgrade" I would take a bit more apart and check the valve clearances... I forgot how much I hate working on "Bucket Shimmed" engines :hehe: ... checking clearance is easy... if you know what size Shims are already in the bucket all is well and the job is quick and easy... but if you don't know the size... you have to take the cams out just to find out what 3 numbers are on the shim :doh:

Lucky me... All 4 valves are barely in spec still after 13,000 miles :

Spec = Intake 0.10 - 0.20mm , Exhaust 0.15 - 0.25mm

Left Intake = ~0.1143mm , Right Intake = ~0.1397mm
Left Exhaust = ~0.165mm , Right Exhaust = ~0.165mm

One of the Exhaust Valve Shims I had to measure (had no numbers...)

Broke 2x 8mm sockets (craftsman tools... need I say more...)... lucky the big chunks of broken metal didn't fall into the engine... would have been really unhappy this evening :lmao:

Need to order new shims : 2x 245 and 2x 250 to bring the Turtle's valves back into spec (as close to 0.20mm and 0.25mm as possible)

Oh... anyone in my area needing to borrow the "Eagle Mike Doohickey Tools" to get your KLR650 "doo" upgraded... let me know :tup:

I will be back sometime in the next few days with a few pics of all the projects going on lately... airbox removal for Uni Pod Filter, Lithium battery relocated, "doo" upgraded, rear rim true/balance, rear rim sealed/tubeless upgrade, rear tire installed, valve clearance check... debating on the "MC Mod" while I'm at it...

[BlackBike]

OK, I'll bite . WHAT DO THE DOOHICKEY DO? It says something about balancing .

[Azhule]

Some kind of "Idler Shaft Lever and Spring Doohickey" that keeps the pixies inside the 650cc engine happy... the exact translation from Japanese to English wasn't the best... either way... if you don't upgrade to the Eagle Mike Doohickey the pixies will tag in the unicorns and all hell will break loose to say the least

And as long as the old Doo is still in one piece... I get a neat tool to remove my inspection covers :hehe:

https://www.youtube.com/watch?v=KIvDoReLbBo

[BlackBike]

So it keeps the tension up on one of those chains right? What is the matter withe the OEM one? Why is the Eagle Mike better? Sorry, can't do videos

[Azhule]

The OE is a Welded design and several mm thinner than the Single Piece Eagle Mike Upgrade... I paid a bit more to also get ride of crap Springs for a Torsion Spring...

[Azhule]

A few pics while I take a rest :D

Pic 1 you can see what all I used to do the project, used the "KTM 990 Tubeless conversion" as a guide to do my project... used "Goop and Seal-All" in a "Blunt Tip Syringe" (used the Blunt Tip Syringe attachment for the Seal-All, removed the Blunt Tip Syringe for the thicker Goop sealant)...

I'm only doing this mod on the rear rim/tire as it has the proper "design" to do such a mod, the front rim will need some kind of "bead/rim lock" if my research is correct :hehe: guess it's just another reason/excuse for me to upgrade to an Excel rim up front :D

Pic 2 is shortly after the valve clearance check and also of the "MC Free Power Mod"...

and pic 3 is of the finished "Tubeless rear rim project", complete with it's new Shinko 705 (tubeless) Tire... used RuGLYDE and 3 Spoons for the easy win :tup: , used about 12 sprays (not even an ounce) of RuGLYDE... what will I do with the rest of the gallon :crazy:

Tire is currently set to 42 psi and so far no leaks!

I will check it in the morning, if no change in the psi I will pull the "valve core" and add 10oz of "Ride-On", re-install the valve core then re-fill with 35 to 42 psi and call it good until I get a flat or need a new tire.

[Azhule]

"No change" in PSI over the last 4 or 5 days (ok... so it went from 42 PSI down to 40.7 PSI, but the ambient temps went from the low 60's down to 20 and below, that accounts for the drop in PSI), so I pulled the valve core and added 10oz of "Ride-On" into the tire, refilled the tire with 34 PSI and I'm officially Tubeless in the rear :p

Removed a nice chunk of weight considering the previous owner(s) had "Ultra Heavy Duty Tubes" installed :hehe:

[Azhule]

Valve shims ordered, will be here Tuesday... considering the "13,000 mile service" complete after that :p

Also ordered some upgraded Barnett Clutch Springs, I noticed Schnitz Racing has a 10% off coupon for "Black Friday/Cyber Monday Deals" and I ordered 2 packs of clutch springs... so anyone with a 1987 - 2015 KLR 650 in my area needing or wanting to upgrade the clutch springs, let me know... I will have an extra pack sitting around ;)

Original clutch springs rated for ~210lbs of clutch pack pressure, EBC is around 220 - 230lbs... the ones I ordered are 280lbs :yay:

Those springs are going to be a perfect combo with my Hydraulic Clutch and any of the future mods I might do while owning this bike (things like Stage 2 Hotcams, 685cc 11:1 compression kit, over sized valves, etc.) :hehe: no more having to worry about power slipping away with those springs installed :lmao:

[BlackBike]

Sounds like your scratching your tinker toy itch.

Are many of these items you speak of been upgraded/redesigned on the latest klr models? 2017 model: https://content.kawasaki.com/content/uploads/products/7469/lzgt24ru.cam.jpg?w=266&h=178&mode=crop

I Remember a few years ago thinking about pulling the trigger on a klr but decided it was to much of an investment for a newb. Still think it's the greatest for what-it-is bikes.

[Azhule]

Are many of these items you speak of been upgraded/redesigned on the latest klr models? 2017 model

Little changes have happened to the KLR 650 over the million years it has been out :hehe: ... 2008 and new bikes have been known to NOT need an aftermarket exhaust header to get extra power, they already have a great design, smooth bends, and little to NO mountain welds restricting flow like the 1987 - 2007 models do :tup: they did beef up the weld on the stock "Doohickey" but it has been reported to fail just as often as pre 2008 KLRs

Other than the "slightly restrictive" exhaust header... a few suspension changes... not much else has changed over the years to my knowledge...

Nothing has ever been "Fixed" (or even admitted to be "faulty") by Kawasaki, it has always been up to the owners of the bikes to fix the few problems that sometimes occur...

We (KLR owners) have been extremely lucky, as several of the owners of big name brand aftermarket parts companies actually ride a KLR 650, most of them ride it daily, so they came out with plenty of stuff to fix any of those 'problems' that pop up :D

[Azhule]

More parts are in!!!

But... they are the wrong ones :lmao: ... my go to motorcycle parts store might have hundreds of boxes with the wrong sized "Front Brake Line" :doh: ... won't know until I get an email/phone call back from them :hehe:

They had a smoking good deal on them, only $24 shipped with the legendary RMATVMC customer service and warranty, so I ordered the front, already had the rear done a long while back.

Was afraid they would be closed, but I remember calling several times after 8am on previous Saturdays and someone was there as always to answer my call... within 2 rings as always too (was under a full ring this time :tup: )

A couple minutes talking to the nice lady, a few pics and a email later... and I feel I will be taken care of as always, will just have to wait a bit longer (holiday season after all)

Anyone want to venture how far this "Front" brake line actually goes? I can tell you it barely reaches the Clutch Lever on the handle bar... I can't for the life of me figure out how to make it go past that and all the way down to the front brake caliper... the brake line in the box is only 20 or so inches long after all :p

[Azhule]

Got a call the other day from RMATV saying, no more 'green front brake lines' in stock and the 'green rear' that they have in stock was low by 1... the 1 they shipped me (the only one mislabeled as a "Front Brake Line"... just my luck) :hehe:

RMATV only called to ask if I would like the brake line in Black or if I would prefer a refund instead :lol: ... "ship me the black one please, the original 1999 brake line is well passed it's service life... what should I do with the green rear brake line I received?"

I was told to keep it... :yay: ... seeing how I already installed SS brake line (black) on the rear not even 6 months back... I won't be needing another one for some time...

Soooo.... anyone in my area want a Tusk SS Rear Brake Line (green)? It was on sale and I only paid $24 for it... Should fit all years KLR 650's, but I ordered it for my 1999 "1st gen model"... might fit dozens of other bikes too... I can take some measurements if there are any takers :D

[Azhule]

Almost done with my Lightweight 'Turtle' errr 'KLR' project...

I got a little bit of extra "spending $$" the other day and noticed Fay Myers Motorcycle World had the Magura Hydraulic Clutch Kit I need for the KLR at a great price... so I ordered it :lol: ... last time I bought one it was a hair shy of $250 with shipping fees :wtf: , this time it was just under $185 for the same kit :clap:

The first Magura kit I had ended up on the Mrs.' Bashan WILL :lmao: that Hydraulic Clutch alone was over 25% of the bikes original cost :crazy: I know... I know... I go bit crazy when I start to modify things

Anyway...

The new kit should be here Monday... maybe Tuesday if FedEx forgets how to do their yob...

Only things left to do for my KLR project is:

Install the new chain/rear sprocket I got a long while back, swap out the old valve shims for the new ones, build and mount a Battery Box, check every nut/bolt I may have touched 'replacing the Doo'... also about time to buy a light weight Lithium Battery, some Titanium Fasteners, and some lighter Rims/Spokes to finish the "weight loss program" :D

Once that's done, I will pop it on the scales and see how much my Tortoise weighs after it's winter time Fasting

[Azhule]

FedEx figured it was easier to have USPS deliver my Magura Hydraulic Clutch Kit... luckily for me it was still delivered "On time" and I received the box today...

Install was extremely fast and easy... as I already did it before and since I never "re-installed" the old cable clutch setup when the Mrs. Bashan took ownership of the first Magura Hydraulic Clutch Kit... I had nothing to remove, and just slapped everything in place in a few seconds :D

Checked the rear tire pressure today too... hasn't budged since I went Tubeless :tup:

Have to fix the Headlight Fuse... I melted way back when I was out riding with the "China Bike Riders: Colorado Chapter", I think while I was bouncing over rocks my finger hit the headlight switch and got stuck between the "High/Low" setting making both lights shine bright overheating the circuit, causing the fuse I put in to melt instead of just 'popping' :doh:

Once I make shift a battery box (and borrow the battery from the Mrs. Bashan), I have my KLR back :yay: