2009 Kawasaki KLX351F project bike [Archive]

SamM

03-22-2011, 06:24 PM

What a great little motorcycle. The 116 mile ride home from Tri-County Kawasaki in Petersburg, WV was a blast. This bike is probably the most fun you can have with 16hp. What a rush! It was a little cold in the mountains but it was great being back on 2 wheels.

At first, I was thinking that the front 17" wheel would be the limiting factor on this machine. It's not! The stock tires are. I'm hoping that a 140mm rear tire will fit on the back. A may also get a 120mm tire on the front. This bike is freakishly fast for it's size. It can easily runaway from most vehicles in the twisties. In a turn, I don't let off on the throttle. It turns in great and you just power through the turn, wide open throttle. It's crazy! I can't wait to hot rod this thing!

Here are the pictures!

SamM

http://img52.imageshack.us/img52/3405/cimg0064q.jpg

http://img836.imageshack.us/img836/3083/cimg0063u.jpg

FastDoc

03-22-2011, 06:27 PM

16HP???

You sell the bike short!

It dynos at 20.5 RWHP. :P

Will try to post link for you.

If you can live with the noise there is 3-5 more HP in there with $400 of mods and about an hour and a half...

FastDoc

03-22-2011, 06:30 PM

On the Area P dyno, the SF was able to crank out 2.5 horsepower more, up to 20.5 ponies at 8,800 rpm - possibly due to a better transmission of power from the street tires than the Sâ€™s knobbies. Torque is up marginally to 13.7 ft-lbs at 7,400 rpm.

Also note the Area P dyno tends to read a little lower than most other dynos...

Here's the rest of the article:

http://www.motorcycle.com/manufacturer/kawasaki/2009-kawasaki-klx250sf-review-87863.html

FastDoc

03-22-2011, 06:32 PM

Testing on the Two Brother's Racing Dyno shows just under 25HP with their (loud ass) pipe, jetting, and airbox mod (snorkel removal).

Like I say if you don't mind the loudness go for it!
:P
I know you will... 8)

Weldangrind

03-22-2011, 07:53 PM

I can't wait to hot rod this thing!

I knew it! :lol:

SpudRider

03-22-2011, 09:49 PM

I can't wait to hot rod this thing!
I knew it! :lol:
X2! :lol:

Your bike looks great in black, Sam! :)

Spud :)

SamM

03-22-2011, 10:14 PM

The May 2009 Cycle World test shows 21hp @ 8100rpm. So, I guess I was wrong. Pretty sure I saw a report that stated 16 to 18hp stock somewhere. Bikeland did a 330cc engine kit, had the head ported by M-Tech, added a 36mm flatside Mikuni carb and a new exhaust. All that work only netted 29.8hp on their test bike. It seems to me that more power than that should be possible with that combo. The salesman at the dealership today mentioned that the Kawasaki KFX400 atv uses the same engine. He said the head was a direct swap. I may look a bit further into that later.

My first course of action is to remove some weight from the bike. I'll be starting with carbonfiber parts from DRC and Light Speed. The cf parts will include frame protectors, rear caliper guard, rear mastercylinder guard, skidplate and fork shields. DRC makes cf air deflectors that have intregal LED signals, so the stock signals, tailight and inner fender will be removed. DRC makes a clear lens taillight that also has intregal turnsignals and a plate bracket. The bike will also get new Moose Racing black aluminum handguards and ProGrip Superbike Gel grips. I may go with a new much smaller and lighter Li-ion battery.

Any engine modifications will have to wait until the riding season it over.
This is now my daily driver. After that, as I said, all bets are off! :D

SamM

SamM

03-23-2011, 05:04 AM

Thanks everyone! :wink:

Wow, this bike is just a blast to ride! I'm still coming down from my 116 mile trip home. It was the most fun I've had on a motorcycle in a very longtime. I took my wife out to dinner lastnight and all I wanted to talk about was the bike. She said, "Wow, you really like that little bike. I haven't seen you this excited in awhile!" Oops, I'd better cool my jets! :oops:

Yesterday, when I rode up and over the mountains I was shivering from the cold but didn't care much as I was having a blast. I had to change up my riding style a little. The front 300mm brake is great. Honestly, it's overkill! One finger on the lever is all you need and you'd better not squeeze much. This thing will stop... NOW! The gloves that I took where KLIM Tomahawk Gore-Tex all-season/all-weather gloves. They're on the bulky side but warm. My index finger covered the brakelever at all times and when I would roll off the throttle, I would gently squeeze the lever a little. That's all that's required! The tight twisties is where this bike is great! I was on the throttle, roll off, brake just a little to set it up and back on the throttle. In the turns that weren't quite as tight, I'd just power right through the turn, keeping the speed up as I exited. The frontend wanted to pogo on me some, most due to the road surface. I may need to fiddle with the settings a little but the rear shock was very good, which is surprising to me. Overall the bike works very well for it's intended purpose. You're not going to win any dragraces with it but get the speed up and you'll leave 90% of most vehicles behind. They simply can't hold as much speed through the corners as the SF can. This bike appears to be breaking the laws of physics as you ride it. My thought was that this little bike just can't be this fast. It doesn't compute and that's what makes it fun. I'm so glad I bought this thing. It's already filthy dirty and I'm hating that. I need to wash it. My house is 1.1 miles up a dirtroad and it's very muddy due to the rainy weather we've been having lately. We have rain and snow in the forecast for the next few days, so I probably won't be riding for awhile. And we have a trip planned for the weekend so that's out. Major bummer! A new bike and no riding! :roll:

Now, we get to have some fun as I mod it up! :D Ok, Weldandgrind you knew it was going to happen! As I said, just bolt-ons for now but the go-fast stuff will happen at some point in the near future. This bike is too much fun to leave stock for very long. New tires won't be far off either. Any thoughts on tires out there? I want something semi-aggressive and very sticky. It must have an excellent wet weather rating. Maybe the Tourance or Distanzia. My search is on. It sure looks like a 140mm will fit on the back. The 120mm front will easily work. At first, I thought that a 19" front wheel might work better for me. At this point, I'll hold off on that and explore the 17" wheel and tire possibilities.

The KLX250 bike is huge overseas. In Southeast Asia it's a cult bike. If you want to see some great videos, go to YouTube and type in D-Tracker. There's a D-Tracker Motorcycle Club in Thailand that posts some great video of their rides. There is also a 125cc version of the D-Tracker and I'm pretty sure both models are fuel injected over there. Europe gets those bikes too. You'll see both the 125 and the 250 in the videos. It's not quite the same bike but you will see the family resemblance.

I'm off to cruise the net and look for parts. More pictures to come later as I start removing some weight from the bike. I'll be placing an order with both Light Speed and Wheeling Cycle Supply (DRC) in the next few days. I'll be calling GEICO today and upgrading my insurance as I only put liability on it to get home. If something happened to it, I'd be very sad and I'd have to have another one. :roll:

FastDoc, thanks for the clarification on the horsepower numbers. Not sure where I saw 16 to 18hp posted. She seemed a lot faster than that on the ride home. The 20.5 and 21hp ratings seem to be closer. Also, is the S model seat comfortable? I was so excited that I forgot to check out the S model that they had on the floor. The SF seat isn't bad but that strap hits me right across the backside. The strap has got to go!

Cheers!

EDIT: I resized the pictures down to make them fit better with the text! Hopefully it looks better now!

SamM

RageHardIntoTheBendies

03-23-2011, 11:06 AM

Sweet ride!

FastDoc

03-23-2011, 11:21 AM

This bike appears to be breaking the laws of physics as you ride it.

As a rider of a similar bike I understand. The S version does a great job in the dirt as you might expect. I'd like to try an SF on the street. With the 50/50 D/S tires even the S model flat out rocks in the commuter and canyon role out here in the desert. I'm pleased to report my mileage has improved to over 50, So I think the snorkel removal has helped. :D

Like I say if you don't mind a loud pipe a 20% power increase is just $400 and a couple of hours away. I have a TBR pipe, with makes the most power but may be the loudest. If I had to do it over again I'd get a Q4 but I do like the HP I have now. I just wear earplugs on every ride every time to keep my tinnitus from worsening. :cry:

As any veteran rider will tell you, it is more fun to ride a slow bike fast than a fast bike slow. 8)

FastDoc

03-23-2011, 11:24 AM

Also, is the S model seat comfortable? I was so excited that I forgot to check out the S model that they had on the floor. The SF seat isn't bad but that strap hits me right across the backside. The strap has got to go!

The seats are the same, and comfortable enough for a 2 hour ride for me.

The strap is held on by 2 8mm head bolts and is easily removed and not needed. I don't know what it's there for. I think maybe its required for passengers in some markets.

BTW have you noticed the slick and ultralight rear passenger footpegs? :D

SamM

03-23-2011, 12:23 PM

FastDoc,
If you don't mind me asking, where did you get your skidplate and how much was it?

Yes, those passenger pegs are super slick. I can't imagine having anyone on the back of my KLXSF, so I'm not sure if they'll stay on mine or not. A bunch of stuff is getting ditched. That goofy toolbag and seat strap are history, as soon as I get some garage time.

The seats looked the same to me. Just wasn't sure. Thanks! I rode mine for over 3hrs yesterday and it didn't bother me much.

I've been looking at headers and mufflers all morning. The FMF parts look very nice and they promise lower dBs but the Muzzy seems to make better power. I've also been on the Bikeland, B&B Restoration and Kustom Kraft websites. The Bikeland project KLX330SM is a very cool bike. I may duplicate their build. B&B makes a 351cc kit but they have only produced about 26hp, no headwork and a 34mm carb. Bikeland and M-Tech made 29.8hp with a 330cc kit, 36mm carb, head porting, Web Cams and the Muzzy system. By using a combination of these parts, I believe 30+hp could easily be achieved. Muzzy doesn't sell their parts individually. I may have to buy the Muzzy system and then sell the header, as I would like to try the FMF MegaBomb header with the Muzzy muffler. Selling my KTM 950 engine should yield me all the money that I need to build one killer little bike. My KLR650 engine is also being parted out to fund more cool parts.

My bike is just for commuting, so I'll be using it as an urban assault vehicle. No off-road stuff for this one. I may go ahead and buy the motorcycle carrier that I have been wanting. This will let me carry the bike in and out of my place without riding it on the dirtroad.

Wow, that didn't take long! :roll:

SamM

http://www.bikeland.org/misc/project/klx/muzzys1.jpg

FastDoc

03-23-2011, 12:39 PM

FastDoc,
If you don't mind me asking, where did you get your skidplate and how much was it?

Happy trails, and about $85. It fit great is well made and engineered and easy to install. Happy Trails is based in Idaho and they are good people to work with. :D

FastDoc

03-23-2011, 12:42 PM

I'd be interested to know the power of the Q4 vs. the Muzzy vs. the TBR. I'd also kike to know the db reading for each.

My stage 2 Dynojet, snorkel removal, and TBR pipe have yeilded considerable performance improvement, but that bike is loud. I won't even wash it without earplugs. 8O

The 'quiet' tip may be here today... :roll:

FastDoc

03-23-2011, 12:43 PM

I might be interested in trading my TBR for a Q4...

SamM

03-23-2011, 01:01 PM

I've dealt with Happy Trails before. Good people! I'll probably just order one of those. The engine is not worth taking chances with.

I haven't read any dB reading comparisons. FMF lists a 96dB maximum on the Q4, with most models coming in below 93dB. They report a 1.5 dB reduction and 3hp increase when using the MegaBomb header.

Sweet ride!

Thanks RageHardIntoTheBendies!

SamM

http://i.ebayimg.com/00/$(KGrHqUOKowE1z5YuDkkBNeCbQo41!~~0_12.JPG

http://i.ebayimg.com/00/$(KGrHqR,!hoE1hdiq1PsBNeCPmrJ4g~~0_12.JPG[/quote]

FastDoc

03-23-2011, 01:05 PM

That sounds too good to be true regarding the header...

I don't know the sound output of my TBR.

I'd estimate somewhere around a million db. :?

RageHardIntoTheBendies

03-23-2011, 03:15 PM

I really wanted (still do) a KLX-SF due to the fact that the 300 barrel is a cheap upgrade and nets you about the same HP as the DRZ400 but with a lighter weight and a 6 speed :D

I also remember there being some other small KLX tweaks you can make, like drilling the vent hole for the crank case breather larger?

Also some carb adjustments for better response like drilling the slide, and removing a coil from the slide spring for less preload.

FastDoc

03-23-2011, 03:38 PM

Also some carb adjustments for better response like drilling the slide, and removing a coil from the slide spring for less preload.

The DJ kit no longer calls for drilling the slide and comes with a shorter, lower preload I presume, spring.

The drilling the vent thing is a new one on me. 300, 331, 351 kits are inexpensive and install in a few hours from what I understand.

david3921

03-23-2011, 03:59 PM

Nice bike, Sam. I really, really wanted one of those when they first came out. I asked my local dealer to call me when they came in. They never did. I saw one at a dealer when I was visiting my children in Missouri. I just couldn't get over the asking price at the time...around $5300. Especially when I got my XF200 for just over $2000 (2 years ago). Now, I see they are going on Ebay for as low as just under $3400 for brand new 2009's. I saw a couple threads on them at Supermoto junkie where they hopped them up. You might want to look over there for some ideas.

RageHardIntoTheBendies

03-23-2011, 04:35 PM

http://www.thumpertalk.com/forum/showthread.php?t=319165&highlight=crank

SamM

03-24-2011, 09:24 AM

Thanks guys! Great information! When I finally do decided to get into the mods, I'll probably replace the stock Keihin CVK with a Mikuni flatside.

I'll check Supermotojunkie.

SamM

suprf1y

03-24-2011, 11:06 AM

I wouldn't.

Nothing wrong with that CVK carb. It's really good for the application. I'd go after a lot of things before I considered swapping it.

SamM

03-25-2011, 01:12 PM

The Keihin CVK and CV are both very good carbs. None of my Buells were fast, until I replaced the 40mm Keihin CV with a Mikuni HSR42 flatside. My KLR650 came with a CVK. It will soon have fuel injection and I would never go back. The Keihin CV and CVK react too slowly to produce good power. They are best left for commuter bikes. Admittedly, that was my plan for the KLX but it's just too much fun. The Mikuni reacts much faster and makes more power. I'd like a little more power. My plan is to convert the KLX for use as a dualsport. The Supermoto wheels will only be used occasionally.

Today, I made the first purchase for my new KLX. It should be all I need to carry a small waterproof bag for light camping trips. My wife bought me a small Eureka personal bivy for Christmas and I already have lightweight gear from my rock climbing days. I've decided to make this motorcycle my new TAT bike. I'm a dualsport guy at heart. I really don't need a Supermoto bike.

SamM

http://img850.imageshack.us/img850/5866/d80e3.jpg

http://img146.imageshack.us/img146/4246/4ecb3.jpg

FastDoc

03-25-2011, 02:15 PM

That's the same rack I bought and I think it's the best. :D

I liked it because it allows the use of the factory tool kit pouch, has no sparp angles or edges, is strong, and powdercoated. It is also better looking, and cheaper than the alternatives. 8)

For me the jetted CVK carb seems fine.
:roll:
I was thinking about this philosophically.

Take a KLX. put in a 351 kit, pumper carb, and exhaust. Now you have the power of a DRZ (stock) and less weight. Same money.

On the other hand it may be better to buy the DRZ (or a Yamaha 250 WR-F) and leave it alone.

Because of this I will for the most part leave my KLX alone as far as performance mods are concerned at this point.

On the other hand a 351 jug sounds good.... :D

RageHardIntoTheBendies

03-25-2011, 03:08 PM

Dang it, local dealer now has new 250sf's on for $4500, sooo tempting!

SamM

03-26-2011, 08:10 AM

Wow, I'm really flip-flopping about whether or not to mod this thing out or not. I went out to the garage yesterday and sat on it, since the weather is crappy again. This is one cool little bike. I called Light Speed and they no longer make all the carbonfiber parts for the KLX. All they have is the frame protects and the skidplate. I'm not sure about a cf skidplate. The Happy-Trail skidplate will protect the engine much better and for $87 is a bargain.

It looks like I may just go with the FMF MegaBomb header and the Q4 muffler to start with. I'll rejet with the DynoJet kit and swap out the stock snorkel for one from a KDX. If there is a noticeable difference, I'll go to the next step and do this in progressive stages. That would be a carb swap to a Mikuni 36mm flatside. Headwork from M-Tech and a set of Web Cams would be the next step. If all this works to bring the bike up to a higher level of performance, that I am satisfied with I would stop there. If not, then a stock KLX300 cylinder and and an aftermarket Wiseco 300cc piston could be the next mod. If that wasn't enough I would spring for the 351cc kit from B&B.

As soon as the weather breaks and I can get some miles on it, I'll report my mileage and impression of the KLX.

SamM

FastDoc

03-26-2011, 11:33 AM

I can't wait to hear your results, and I'm interested to see if you can stop short of a Stage 3+ modification. :P

I like your ideas for the mods but this is what I may be able to contribute.

I think the Q4 is the best choice in a quieter muffler, and the performance advantages of a more straight through design like my TBR are likely not worth the extra noise.

I have heard, for what that's worth that the Power Bomb does add some power for no more, and maybe even less noise :D . Indeed I'd be interested if you could do an experiment for me if you go that route. I'd like before and after noise and SOP power evaluations of the jetted and piped bike before and after the PB if you were willing. :lol:

No need to go to the KDX snorkel. If you look at the geometry of the airbox the snorkel adds only a fraction of an inch to the top of the airbox to keep water out. If your crotch is dry on this bike so is your airbox. I can report no perceptable noise increase with the snorkel simply removed.

Some people remove the backfire screen. I did not.

Propperly piped and jetted I bet you won't see the need to change the carb. To get more power other than Stage 2 mods, the cheapest and best way is a 300, 331, or 351 kit. 8)

You will indeed NEED MPG's just to have the range to make it to the next gas station! My lawnmover has a farther range than this thing.

SamM

03-26-2011, 12:35 PM

FastDoc,
I'm looking at the MegaBomb rather than the PowerBomb. There's about a $50 difference between them. The MegaBomb header is advertised to give a 1.5 dB decrease in sound. The PowerBomb add does not list a decrease in sound.

My thoughts on going with the bigger 351cc bore are that I would probably need a bigger custom pipe and muffler. The FMF MegaBomb is still sized for the 250cc bore. It's more than likely going to be the bottleneck with the 351cc big bore cylinder. There is not a big increase on power when going to the bigger bore over just a pipe and muffler. From 26 to 29.8hp isn't much. The FMF exhaust system would probably be a good match for the 300cc engine kit. That's my reasoning for starting with the smaller bore first. We'll have to see! I'd like to dyno the bike with just the exhaust mods first, then with the headwork and cams. Once I see how this effects mileage, I would go forward.

I just don't want to have the bike down for any length of time.

SamM

suprf1y

03-26-2011, 07:28 PM

I've had my KLX for 3 years. I do a lot of fairly fast single track, and always ride the bike there.
If I can offer any insight, it would be this,
I did the jetting, and carb mods first, including drilling the slide, a 300 needle, and removing the lid. This helped a lot. Next I did a Muzzy can, and that made a big difference. Removing the backfire screen made a far bigger difference than I expected. I'm not sure why, but maybe the air signal is stronger, and the slide opens faster, or maybe my jetting was a little off, and the extra airflow corrected it, but it was one of the mods that made a very significant difference. If I bought another one, it would be the first thing I did. The FMF header, and muffler were icing on the cake. I'm quite happy with the power now, but since the stock cams are quite mild, when i go after more power, cams will probably be next, followed by a 300 barrel, and piston.
With my bike, the way it is now, I was able to beat (barely) a KLX 300 with carb mods and FMF muffler in a drag race.
I am very happy with the bike.
My mods now

FMF Powerbomb header, and Q4 muffler
132 Main, N1TC needle, drilled slide
Airbox lid and backfire screen removed

SamM

03-26-2011, 10:03 PM

Thanks suprf1y! That's great information.

SamM

SamM

03-30-2011, 07:33 PM

Just ordered new dualsport wheels for the KLX. Black Excel premium rims, Superlaced with stainless steel nipples and heavier ss spokes, Neutech TUbliss wheel seals, and TKC-80 tires were just ordered from Woody's Wheel Works. These are sized 21/18" and will turn my KLX250SF back into a dualsport. I removed the KLX250SF stickers a few days ago. Soon there will be no evidence that it was ever a Supermoto bike, aside from the 300mm front rotor. The TKC tires are more of a 60/40 dualsport tire and should work well for my 20 mile commute. A new front fender, kickstand and rear shock are all needed now. I'll be ordering them shortly to have them on the bike once the new wheels arrive. The standard KLX250S rear shock will give me 9.1" of travel front and rear. New Moose Racing aluminum handlebars and handguards are also on my list of things to get this week.

We still have crappy weather here in WV for the next 2 weeks. I'll have the wheels back before the weather gets nice, so this shouldn't effect my riding.

I've also recently removed about 5lbs of crap from the bike with much more to come.

Stay tuned as I wick this thing up into a 351cc beast. :D

SamM

Weldangrind

03-31-2011, 12:47 AM

I think that the TuBliss system is the way to go, especially on a DS.

I`m totally focused on the 351cc goal. :D Is that simply a big-bore kit, or are you splitting case to stroke it?

RageHardIntoTheBendies

03-31-2011, 12:56 AM

what are you doing with the 17" rims etc?

Weldangrind

03-31-2011, 01:24 AM

That's funny, Rage. I was waiting for you to ask that question. :lol:

suprf1y

03-31-2011, 07:32 AM

351 is a big bore kit

http://bandbcyclerestorations.com/Home_Page.php

Not a bad price, for what you get.

SamM

03-31-2011, 08:45 AM

Rage,
Woody's Wheel Works is taking my stock 17" Excel rims, spokes, nipples and the stock IRC Winner tires in on trade for the new wheels and tires. It looks like I'm going to get a pretty fair chunk taken off my total. Josh at Woody's said I'd get something like a $300 credit IIRC.

W&G,
The 351cc engine kit from B&B is just a bore increase. My plan is to do it over one weekend, so as to not have any real downtime on it. The cams and headwork will wait until next Winter, if I decide they are necessary. The big bore kit will be used in conjuction with a new FMF exhaust and probably a new Mikuni TM-36 flatside carburetor. Overall, I think this is the way I want to go for my build.

From what I'm reading the 351 kit doesn't effect the reliability of the bike. I hope that's the case! It may seem that I am going full tilt but what I really want is just a reliable but more powerful trailbike. It needs to compete in both price and power with a new DRZ. Hopefully, it will come in lighter and cheaper than that alternative. My next big obstacle is to overcome the fuel capacity or lack of, I should say. Of course, I will also be looking to drop a bunch of weight. I'm considering dropping the stock gauge pod, turnsignals, inner fender and a few other things. My grinder may also get a workout. :wink:

suprf1y,
Honestly, I think the 351 kit is overpriced. It's $721.52 plus shipping which seems pretty pricey to me. All that's there is a piston, a sleeve, some machine work and the new installation parts (wristpin, circlips, and gaskets). Those parts are fairly inexpensive, less than $75. The new piston should cost around $80 to $100. What we come away with is about $550 worth of machine work and sleeve. Sure he's got intellectual property there, as he pioneered this conversion but that's rather expensive machinework. I'll gladly pay his prices, as I'd like to have these parts for my motorcycle but I have looked at less expensive alternatives. I hope it brings everything to the table that it promises. I'd like to see 30 ponies! :D

SamM

http://img849.imageshack.us/img849/4610/dsc01577aq7ei.jpg

Weldangrind

03-31-2011, 10:48 AM

How does that work? Do you give him your cylinder on exchange, or is it up to you to find a good shop to replace the sleeve?

FastDoc

03-31-2011, 12:00 PM

351 is a big bore kit

http://bandbcyclerestorations.com/Home_Page.php

Not a bad price, for what you get.

Direct bolt on. Supposed to be a 3 hour or less job start to finish. I thought it was in the $550 bracket. A good value in both time and money as I understand it.

FastDoc

03-31-2011, 12:04 PM

From what I'm reading the 351 kit doesn't effect the reliability of the bike. I hope that's the case!

Not an issue at all. Remember the bottom end is supposed to be 300+cc. The 250 is a reduction from what it was designed to be.

I've read of NO ISSUES from the BB kits, including people with 30,000+ miles on them. :D

SamM

03-31-2011, 01:20 PM

I thought it was in the $550 bracket. A good value in both time and money as I understand it.

FastDoc,
Nope, if you read the fine print you realize that there is a $175 core charge on the cylinder that they send in the kit. You send your standard cylinder back to get the core charge refunded. They mention that lower down the page. He also charges a a 3% surcharge for using PayPal. That's why I stated that this is fairly pricey.

W&G,
You send in your cylinder back to them on exchange. They'll send me a freshly bored and sleeved core cylinder that was on someone elses bike. Of course, you have no idea of the history of the core but I suppose it's fine as the boring would fix any problems. Hopefully, there are no cracks in it. I may just send them mine cylinder and wait for it to be machined and sent back. That way I get my new cylinder back. That means unwanted downtime that I am trying to avoid.

SamM

suprf1y

03-31-2011, 05:38 PM

SamM

03-31-2011, 07:38 PM

It's $527. You have the choice of making it more expensive, but that's YOUR choice.

There is no intellectual property. It's just a big bore kit.

Keep in mind that there is a fair bit of labor, and expertise involved, and good luck getting a quality piston and rings for $80-$100.
He bores your cylinder if you send it in, or a core cylinder if you prefer. It's your choice.

I have a similar business, and trust me, those prices are more than fair.

On the core charge, I charge $150 core, and in almost 10 years, and hundreds of jobs, I have received only 3 cores back. It really pisses me off that my customers do that. Bill and I have had this discussion, and he has the same problem. WE NEED THE CORES TO KEEP PROVIDING THIS SERVICE. People just don't seem to care.

suprf1y,
No, my choice is whether or not my bike is down one weekend or two weeks while I wait for parts. I never said it was a bad deal. What I said was that it was fairly pricey. Over $700 is fairly pricey to me. Maybe it's not to you! If I could send him $527.45 and be done with it, I would think it was a great deal. That's not the case. Maybe the core charge was an afterthought because people weren't sending cylinders back. It doesn't matter, because I still have to pay it! My engine isn't going to come apart until the new parts arrive. Until I send in the core my price is still $721.52 when I use his prefered payment method of PayPal. I'm just stating the facts here. We can agree to disagree on the price that's fine.

I have a shop full of Wiseco piston & ring kits that I paid much less than $80 for.

What I meant by intellectual property, was the legwork he did sourcing a sleeve manufacturer and then, the proper sleeve from that manufacturer. He had to send them specs on what he wanted. That took a little thought and he basically designed it.

I've done a good number of engine upgrades and I know what's involved. Most of mine involved Harley engines thought.

SamM

suprf1y

04-01-2011, 01:08 PM

The price is the price.
It's $527. If you choose to pay the core (an afterthought? Core charges are standard in the industry), so you can get it quicker, that's your choice. Please don't be one of those ignorant people that keeps it. We need the cores to support other customers.

I'll take a dozen KLX Wiseco big bore pistons for $80, and even give you $100 tip.
Thanks for coming out, and adding so much to the discussion.

SamM

04-01-2011, 10:16 PM

Yesterday, I disassembled my brand new motorcycle and removed the wheels. The brake rotors and rear sprocket were then taken off. Shipping to Denver was $77 and some change. The wheels will arrive Wednesday at Woody's Wheel Works. Thankfully, I've done this before and had the right boxes.

Today, I called Zack at Woody's. My Neutech TUbliss system, the new TKC tires and Excel rims are there and waiting on the wheels. Turnaround should just be a couple of days. Woody's shop is the only one that I would trust to do this. His Superlacing process makes these wheels strong and spoke adjustments a thing of the past. He is also doing the wheels for my new KLRE650.

Can't wait to get them back! :D

Pictures in a week or so!

SamM

SpudRider

04-01-2011, 10:37 PM

...Today, I called Zack at Woody's. My Neutech TUbliss system, the new TKC tires and Excel rims are there and waiting on the wheels...
Have you employed the TuBliss tire system before, Sam? I am considering the TuBliss system for my XR650L, but I hear some people have problems with the 120 psi, high-pressure, inner bladder. :?

Spud :)

SamM

04-02-2011, 06:42 AM

No, I haven't. But I have heard a greater number of good reviews for the TUbliss compared to bad reviews. The smaller bike seemed to be the better test platform for it. I'll make my decision based on how well it does on the KLX. Woody did a set of 19/17" tubeless Excel wheels for my KLR a few years ago. I sold the 19" front wheel but I still have the 17" rear wheel. I'll be sending that wheel back to Woody to have it made into an 18" rear for the KLRE. We're going to try fitting a Heidenau K60 140/80-18 tire on the back with the TUbliss system. The frontend is off a 2008 KX450F and uses a KX non-speedo hub. He'll make a new 21" Superlaced wheel on that hub. If the TUbliss doesn't work with the bigger rear tire, we'll change up the sizes.

The KLRE650 is going to be a great bike. The parallel-twin with 65hp, EFI and a 6-speed will really change the KLR into an Adventure Tourer. My plan is to not be limited with this bike. I have spare wheels that will get Dunlop 606 tires for off-road use.

SamM

SamM

04-07-2011, 11:08 PM

My parts have started to arrive and I'll be tearing into the bike tomorrow. In addition to the new black 21/18" Excel wheels I have ordered: an eBay
rear rack, FMF MegaBomb header, FMF Q4 muffler, Moose Racing 520FB chain, 14/42 sprockets, UNI airfilter, Dynojet jet kit, Moose Racing KX bend aluminum handlebars, aluminum throttle tube, ProGrip Superbike Gel grips (the only grips I use) and aluminum rear axle adjusters. The next additions are: a Happy-Trails skidplate, new footpegs, a small windscreen, TorqueMaster sparkplug, new rear taillight, 12 o'clock labs intregal turnsignal circuit board and to drop a little more weight from the bike. I have also purchased a spare rear SF shock. The shock will be sent to Cogent Dynamics for a rebuild. They should be able to get 9" of travel from it, to match the front travel.

I'll post pictures as soon as I have a roller.

SamM

FastDoc

04-07-2011, 11:41 PM

Wow you're off to a good start!

I highly recommend the Happy-Trails skidplate.

I am interested to hear about the windshield you ordered... :P

SpudRider

04-08-2011, 02:22 AM

Wow you're off to a good start!

I highly recommend the Happy-Trails skidplate.

I am interested to hear about the windshield you ordered... :P
Sam never lets any moss grow under his feet, Doc. ;) Please do keep us updated, Sam! :)

Spud :)

SamM

04-08-2011, 11:39 AM

Thanks SpudRider & FastDoc! :wink:

When I purchased this motorcycle, I saved myself a great deal of money. That made the decision to jump into the build much easier. Actually, I just switched the lights on in the garage and I'm getting ready to hit it. Right now, I'm sitting here waiting to hear if my wife will have a job next week. The government shutdown would close her department on Monday. It doesn't look good! :roll:

Anyway, it shouldn't take me very long to finish this project. I'll be calling Zack at Woody's here in a few minutes and then Happy-Trails later on today. Once the wheels get here, the bike will be rideable and that's the most important thing to me. The downtime sucks! As long as I have the wheels, the exhaust and a lot of the other parts can wait, until I have more time to rejet the bike. Which I'll need to do as soon as the exhaust gots on it. Most of these parts are still on the way to me. The wheels may ship today that's why I need to call Zack.

Also, I'm really torn over the 351cc engine kit. I have the funds to order the B&B kit. However, the downtime associated with having my stock cylinder machined or the condition of the core cylinder that I would get, if I go that way, is my main concern. At this point in time, I'm not sure what I'll do. Perhaps just doing the bolt-on mods would get me where I want to be. I'd like to be in the 26 to 30hp range. If the bike does in fact make 21hp stock, I think this would be reasonable.

FastDoc, just to clear it up. The windscreen is a future addition. I have not found anything yet that will work. I am looking though and I'll report what I find.

Stay tuned!

SamM

FastDoc

04-08-2011, 11:59 AM

It seems to me a company could make a small windscreen to replace the white 'number plate' above the instrument cluster.

Prayers sent for your wife. A shutdown makes BOTH political parties look like asses and hurts a lot of innocent people.

I'd go for the 351 kit. I bet almost all the cylinders they have are from guys like us with new bikes. IF they had ANY damage it would be to the bore, which is removed in the process. The rest of the jug for the most part is inert.

You'd have about the ultimate small D/S bike. It would easily cruise 80, bust the ton, climb anything any other bike can, have great suspension, decent comfort, light weight electric start. Last I checked that's about ALL the good qualities a bike can have!

Just imagine yourself in the West VA mountaians, tight uphill left hander, on the gas, pulling hard, front wheel held down only by your weight over the bars, exhaust echoing off the canyon. (I think its called a 'draw' in your neck of the woods. :wink: ) Life is good!

FastDoc

04-08-2011, 12:00 PM

Plus I bet you'd leave a stock DRZ in your rear view mirrors. 8)

SamM

04-08-2011, 12:59 PM

We call canyons "hollers" where I live. :lol: You have to remember that the Appalachian Mts. are older and more eroded that the Rockies. They are still pretty steep and rocky though. Plenty of places to hurt yourself, if you're not careful.

She just got this job this January, after losing her previous job in Feb 2010. I feel bad for her. In June, I will have 20 years in with my employer. Eight more until retirement. I hate that it comes down to a political slugfest. We'll make the best of it. Everyone in her office is upbeat about it. It will affect those that can't afford it much worse than us.

Of course, you're right about the core cylinders. I suppose that I could take one afternoon and rebuild the engine with the new kit. Making the KLX faster than a DRZ would be a major benefit. I'd like that and it would shut my buddies up. We'll see!

Just got off the phone with Zack. The new wheels will cost me $850 plus return shipping. Around $900. They gave me $450 trade-in for my stock 17" rims, tires, spokes and nipples. This price includes new 21/18" Excel rims, Neutech TUbliss system for both wheels, new TKC-80 tires, bigger stainless spokes and nipples, all the machine work associated with the Superlacing process and the labor charges for the all teardown and reassembly work. The new wheels are expensive but well worth the price. These are true tough enough for Baja wheels that will handle whatever I put them through.

SamM

FastDoc

04-08-2011, 01:10 PM

Those sound like professional race quality wheels. Plus it seems like a fair core value on your original wheels.

Also, by listing your bike as a KLX350 in your sig line you are morally obligated to install the 351 kit. 8)

I consider it but to be honest my bike runs like the dickens right now and I don't want to fix something that's not broken.

katoranger

04-08-2011, 02:41 PM

I am in the same boat as your wife Sam. Fortunately our leave is prefunded and I can use it. Nearly 300 hours saved.

SamM

04-08-2011, 03:28 PM

katoranger,
This two party system seems to be getting out of control. They simply will not compromise. Honestly, I don't think they know what they are doing or what the long range repercussions of going down the wrong path are. Going further and further into debt and printing more and more money isn't the answer. Cuts are hard and we have all done it, at some point. It's hard to tell our kids, no! You're a smart man to save your time like that! Awesome! As I said, we'll be fine. I work everyday! Well, it seems like everyday.

FastDoc,
I wanted to beat everyone to the punch on that one! :) I like the KLX350F designation. The S was dropped because it's no longer a Supermoto. The lone F is sort of a takeoff on the KX250F. More of an off-road model with the 21/18" off-road wheels. It's goofy but I think the designation should say something about the bike. Yes, Woody knows his stuff. These ARE race quality wheels. Zack will ship the wheels out to me on Tuesday. I'll try to post pictures next week.

I spent today putting on the new Moose Racing handlebars, handguards, aluminum throttle tube and gel grips. It looks pretty good.

SamM

katoranger

04-08-2011, 03:54 PM

I am following along. This could be a future bike for me.

FastDoc

04-08-2011, 05:08 PM

I am following along. This could be a future bike for me.

Don't delay! I LOVE my KLX! Great value. See if maybe you can still score a deeply discounted '09.

FastDoc

04-08-2011, 05:09 PM

SamM.

I assume your last name starts with an 'M' so I vote for a KLX350M.

katoranger

04-08-2011, 07:01 PM

I will have to delay until other things are paid for. Got me a scooter for the meantime. Also that means some used ones will be on the market for china bike prices.

Weldangrind

04-08-2011, 10:11 PM

Prayers sent for your family Sam. :)

SamM

04-08-2011, 10:39 PM

Thanks for the prayers! She's with Homeland. That's all I can say! She's a smart girl. It will all work out.

SamM

SamM

04-08-2011, 10:41 PM

This little motorcycle is going to be a lot of fun! I highly recommend getting one, if possible.

Earlier, I was talking with Rick at Cogent Dynamics. He just bought a KLX250 too. I'll be sending my spare SF shock to him as soon as it arrives. He has already reworked a couple of them. We are looking to get another 1" of travel out of it. This will give me just over 9" of travel front and rear.

Rick installed a 300cc cylinder and piston from Kawasaki. He said it didn't make a big difference but it did make all the difference. The stock 300cc parts may be all I need.

See there I go again!

Yes, my last name starts with M.

SamM

Weldangrind

04-08-2011, 10:44 PM

Sam, we know that 300cc might be all you need, but it isn't really all you want. :D

Weldangrind

04-08-2011, 10:45 PM

I will have to delay until other things are paid for. Got me a scooter for the meantime. Also that means some used ones will be on the market for china bike prices.

I'd also like to congratulate you on banking time. It will pay off if the shut down moves forward.

JTCAndrew

04-08-2011, 10:55 PM

Breaking NEWS - NO Government Shutdown!

Weldangrind

04-08-2011, 11:04 PM

That's really good news, and an excellent excuse for a thread drift. :lol:

I was following the progress on CNN and Fox earlier today, but I haven't checked in awhile. IMHO, the Republicans will come off looking like they're cooperative in the big picture, rather than risk playing political football with families. I heard that if the shut down had moved forward, families of deceased military personnel would not receive death benefits. 8O Not sure if that's factual or not.

Back to your regularly scheduled thread...

SamM

05-11-2011, 03:36 PM

A quick update: The bike is coming along nicely. Here's an earlier picture taken a week or so ago. It now has the complete FMF exhaust on it and carb rejetted with a Dynojet kit. The bike runs great. I'm replacing the chain probably tomorrow. My temporary tag runs out tomorrow, so I'll be running into town to transfer plates.

Still much to do!

SamM

http://img153.imageshack.us/img153/4029/cimg0068w.jpg

SamM

05-11-2011, 03:42 PM

The new Superlaced Excel wheels from Woody's Wheel Works. These use the Nuetech TUbliss wheel seals and have TKC-80 tires. The knobbies are actually pretty nice on the road. Not too harsh at all.

SamM

http://img690.imageshack.us/img690/5656/cimg0066gb.jpg

http://img815.imageshack.us/img815/6867/cimg0067.jpg

Weldangrind

05-11-2011, 08:46 PM

It looks really good. 8)

You say that it runs well, but have you noticed much of a power improvement?

SamM

05-11-2011, 10:50 PM

The FMF MegaBomb header and Q4 muffler are advertized as adding more power. I feel as if it gained a few horsepower. It doesn't feel like a big addition but it runs better than it did before. Acceleration has improved but I haven't had a chance to ride it much. My conservative estimate is that the bike has gained 3 or 4hp. That would put it into the 20 to 25hp range, depending on who you believe about the stock hp rating. I have a hard time believing the bike comes stock with over 20hp. The snorkle was also removed and I added a UNI filter. A cutdown KDX snorkle will go on later, as I plan to ride this one off-road.

The new wheels have made a huge difference in the overall feel of the bike too. It really feels like a completely different motorcycle.

The next plans are to start dropping weight from the bike. I have seen a great deal of stuff, that I will not use or need. A new battery is at the top of my list.

SamM

FastDoc

05-11-2011, 11:19 PM

Weldangrind

05-12-2011, 01:17 AM

In what way are the wheels an improvement, Sam? I never considered that the feel would change.

SpudRider

05-12-2011, 03:21 AM

The wheels, and the entire bike look great, Sam! Please keep us updated regarding your impressions of the TuBliss system, and the TKC80 tires. :)

Spud :)

SamM

05-12-2011, 03:00 PM

Have you made the 351 conversion already? I see your sig...

I agree on the exhaust and intake upgrade improvement. I'm figuring 25 HP.

I plan to run a K&N to get a hair better flow. I love my KLX. This bike stays in the stable. This, the GS750, and the Gold Wing are with me for the duration. :D

FastDoc,
No, I haven't done the 351cc conversion yet. That's the overall project goal. That work will most likely wait until the snow flies again. The headwork, cams and new carb will all happen then.

In what way are the wheels an improvement, Sam? I never considered that the feel would change.

Weldandgrind,
The new wheels lift the bike a little and the bike is less twitchy. It's more neutral now. The 17" wheels made the bike drop into a turn very nicely. Which is good but it's a little more aggressive than I like in such a small package. With the limited power of the 250cc engine, it's not the best combination. A Supermoto type bike is a lot more fun with a lot MORE power. My 2004 KTM 625SMC was a real urban assault vehicle. In the twisties it was a real sportbike killer. To me, a dualsport just feels better. It's very subjective, I know. Make any sense? :roll:

The wheels, and the entire bike look great, Sam! Please keep us updated regarding your impressions of the TuBliss system, and the TKC80 tires. :)

Thanks Spud!

It's really a great little bike for the money. I basically have 6K in it so far. Maybe a little more. But I'll get a good bit of use out of this thing. I'm getting some mixed information about the final drive. It's listed in the service manual as a 525 chain but apparently it's a 520. I bought a Moose Racing 520FB chain but I broke the masterlink the other day. Ripped the chain right off the bike. I was fortunate not to get hurt. Just got the replacement links to put it back together. I'm off to do that now. The only casualty was the plastic chainguard. It's history. Shredded it into about 6 pieces. A new chainguard, KLX250S footpegs and a few other little things are on my list to order tonight. She'll be good as new!

The TKC tires seem great on the highway. My riding has been limited due to my stupidity of installing the masterlink backwards! :roll: Just wasn't paying attention as I know better and have done it many times. The Tubliss system hasn't lost much air yet. I'll need to fire up the air compressor and top it off. Hopefully, the weather will cooperate and I'll get to put some miles on it this weekend riding to work.

SamM

suprf1y

05-12-2011, 08:43 PM

I bought some wide pegs for my KLX250s on ebay. I wasn't sure how I'd like them, but since they were cheap, I went for it, and love them.
I can try to find them if you want.

SamM

05-12-2011, 09:08 PM

Sounds good suprf1y! Thanks!

Ok everyone, here's the new FMF MegaBomb header and Q4 muffler. This evening I fixed the chain and took a short 20 mile ride. Everything is back on track and working well. The bike sounds great. There is a slight pogo in the frontend. It might be from low tire pressure. Haven't checked the air pressure yet.

A few pictures of some of the stuff that I have changed.

SamM

http://img36.imageshack.us/img36/1860/cimg0100f.jpg

http://img856.imageshack.us/img856/1097/cimg0101r.jpg

http://img863.imageshack.us/img863/141/cimg0102.jpg

suprf1y

05-12-2011, 09:15 PM

Ask and ye shall receive

http://cgi.ebay.ca/Foot-Pegs-1994-2007-Kawasaki-KLX-250-300R-650-/230619163336?pt=Motorcycles_Parts_Accessories&hash=item35b1f92ac8#ht_2760wt_959

My KLX

http://i118.photobucket.com/albums/o120/suprf1y/GEDC0027-1.jpg

SamM

05-12-2011, 09:51 PM

Looks great suprf1y! These bikes are great fun. I love mine. Can't wait to get the engine redone and do a little suspension work on it. Cogent Dynamics is reworking my spare SF shock now. Should be done shortly.

SamM

Weldangrind

05-12-2011, 09:54 PM

Weldandgrind,
The new wheels lift the bike a little and the bike is less twitchy. It's more neutral now. The 17" wheels made the bike drop into a turn very nicely. Which is good but it's a little more aggressive than I like in such a small package. With the limited power of the 250cc engine, it's not the best combination. A Supermoto type bike is a lot more fun with a lot MORE power. My 2004 KTM 625SMC was a real urban assault vehicle. In the twisties it was a real sportbike killer. To me, a dualsport just feels better. It's very subjective, I know. Make any sense? :roll:

It sure does. I had forgotten about the size difference; I was focused on the aftermarket rims. I've never ridden a supermoto, but I can imagine that you'd want a good amount of power to pull you out of an agressive corner if the bike leans hard.

FastDoc

05-12-2011, 11:50 PM

My KLX and I routinely pull some stupid lean angles, on the stock D/S tires! 8O

I say a D/S is better on the street than a SM is in the dirt so that's the way to go for me.

I honestly like my KLX as much in the twisties as I do on the trails. :D Like I say this bike is a keeper. Plus, everyone knows RED is the fastest color. 8)

Sam, what's your take on the Q4? Not too loud?

SamM

05-13-2011, 01:28 AM

Red may be the fastest but black is cool! 8) Everyone knows real bikes are black! :D

Honestly, it's not too loud for me! The bike is just about perfect with the Q4 on. The bike sounds healthy but not loud. You can hear the engine compared to stock that's for sure. If I need it to be a little more quiet, like maybe in town. I just let off the throttle a little and it's ok for passing through congested areas with law enforcement. She does have a nice burble now but it's not overpowering. Once the KDX snorkle is installed the sound will quiet down some. I can see that the 351 kit will wake the bike up. The decibels will probably go up after that kit is installed. Just a guess.

We have big plans for this bike. Not much will happen for awhile now that I am actually riding it. But if anyone has any ideas about how to remove some weight, please post any suggestions. Shortly, I will start cutting tabs and pieces off the frame. There are many small metal tabs that will not be reused and small parts may be lightened, if I can see justification for it. Trust me it adds up. I got my 2008 KLR down to 345lbs. Like many of you, I will be using this bike off-road. Keeping or actually getting the weight down is paramount on this project. At this point, I'm thinking about not replacing the stock chainguard, that was recently shredded by the chain. I see no reason to replace it. I have a bag of parts that have been removed. The bag holds, bolts, the steel handlebars, grips, the shreded chainguard, reflectors, etc...

The gauge pod no longer works with the 21" front wheel. Meaning the speedo reads very low. So low, in fact that it's not useable anymore. I didn't receive an owner's manual with the bike, so I have no idea if it can be reset for the new 21" wheel diameter. My dealer has been contacted about it, by both me and Kawasaki but still no manual. If the gauge cannot be reset to work with the 21" wheel, I will remove it and install my Trail Tech Vapor on the bike. The headlight and the stock headlight switch may also go away. I have better parts to use. If the gauge pod goes, so will the stock headlight.

Many other things will be changed! :roll: Seriously, please post any thoughts that you may have about weight loss! I want this one to be more like an MX bike. LIGHT! I may also add the backup kickstarter kit and offset that weight gain with a lighter Li-ion battery.

SamM

Weldangrind

05-13-2011, 01:37 AM

If you never plan on carrying a passenger, it's ok to delete the chain guard.

I can't think of much more that would lighten the bike, other than perforating the skid plate.

SpudRider

05-13-2011, 01:56 AM

I bought the same, extra-large foot pegs as SuperF1y, and installed them on my Honda XR650L; I like them very much. :) If you want to shed weight from your bike, I highly recommend you purchase a Shorai battery, Sam! ;) I dropped 5 pounds from my XR650L by substituting a Shorai battery for the stock battery. :)

http://advrider.com/forums/showthread.php?t=666195

Spud :)

SamM

05-13-2011, 02:12 AM

This bike will NEVER have a passenger on it. The passenger pegs will probably go too. I've already had to bend the right steel footguard out of the way to fit the muffler. Tight quarters in that area. The footpegs on this bike are beautifully designed but I will never use them. The angle grinder will take care of them. Same with the helmet lock and all those little net tabs under the seat. It all goes! The passenger strap on the seat has already been removed. It was directly under me. Totally useless. The metal tabs that hold it to the frame will be cut off.

There really is much more. The kickstand safety switch, soon will be GONE. I hate those things. They always fail given enough time. Don't need it. Don't want it. The stock inner fender, taillight and all the turnsignals will be replaced with a DRC Edge tallight and intregal turnsignals. I may use HDB handguards and LED front turnsignals. That way nothing sticks out to get ripped off.

I was very disappointed that Light Speed has stopped making many of their carbonfiber parts for the new KLX250. I could have removed a lot with that stuff.

As soon as I start digging into it I'll find more. Yep, the stock battery will be replaced with a Li-ion battery. I've been looking a several different manufacturers of those.

SamM

dmmcd

05-13-2011, 08:02 AM

Is the chain seriously a 520? That seems way overkill for 25 to 30 hp. My SV650 puts out 70 hp and many people use a 520 on them. Might be one way to save some weight and rotational mass if there are any conversion sprockets to go with a smaller chain size.

Shorai battery can save 8 lbs., I've read a lot of really good reviews about them.

If money is no option and you are really concerned about a few ounces here and there, they sell Ti fastener kits to replace all the bolts and hardware.

I think the biggest way to loose significant weight on a bike is to eat less candy and go for a run every now and then... :wink:

I've read a lot about the turbo kits on the Yami's, I bet they would fit on the Kawi with a little tweaking... 8O

The bike looks beautiful.

suprf1y

05-13-2011, 10:32 AM

I think the heaviest thing on the KLX is wiring. Unfortunately, you can't lose too much of it. I like my KLX so much, I've been looking for a street plated KLX 300 lately.
Imagine 50 more cc, and 60 pounds less weight?
I ride a lot of single track/hare scramble loop, and have a riot on it. If I do a few days on the KLX, then hop on my KDX 220, it feels like I've picked up 25 lbs of muscle :lol:

FastDoc

05-13-2011, 11:43 AM

The footpegs on this bike are beautifully designed

Yes they are. I was impressed by them.

Maybe delete the starter, go with an even smaller and lighter Shorai battery, and add a kickstarter? Mind you this is not for me, as I value The Button. When I stall the bike it's usually in some crappy spot where it's hard to kick start.

The strap on the seat is silly. I don't know what it's for. Maybe some country requires it?

I have the owner's manual and there is nothing in there about calibrating the speedometer. My guess is that there are two versions, one for each wheel size. It could also be that the difference is in the sending unit. If that's the case you'd have a quick and easy way to swap it out.

The TT Vapor dashboard might be a few ounces lighter, but I don't think enough to matter if you can calibrate the existing unit.

FastDoc

05-13-2011, 11:46 AM

I think the biggest way to loose significant weight on a bike is to eat less candy and go for a run every now and then.

Ain't that the truth.

Back in the day I was a competitive bicyclist. The tech weenies used to pay big bucks to get a part that weighed a few grams less than the stock part. The way I see it you could save the same weight by skipping one desert and save a lot of mone in the process. 8)

SpudRider

05-13-2011, 11:52 AM

Without a doubt, the easiest, cheapest, most effective way to lose the greatest amount of weight from any motorcycle is to substitute a Shorai battey for the stock, lead-acid battery. I shed 9 pounds of highly-placed weight off my XR650L when I removed the battery box, and performed my Shorai battery relocation. :)

http://advrider.com/forums/showthread.php?t=666195

Spud :)

SpudRider

05-13-2011, 12:08 PM

FastDoc

05-13-2011, 12:21 PM

SpudRider

05-13-2011, 12:32 PM

But you'll have more muscle to lift it. 8)

The ideal answer is to lighten both the bike and the rider. 8)

Of course some people are already in good shape to begin with and don't need to lose weight. Rare, but it happens. :roll:
Once again, I agree, oh wise physician! :) Your entire quality of life will improve if you lose weight, and get in good physical condition. ;) However, the bike is still easier to maneuver, and pick up, if you can shed unnecessary weight from it. If one wants to make his bike lighter, I'm convinced the Shorai battery offers the greatest return for his investment. ;)

Spud :)

SamM

06-04-2011, 08:27 AM

Well, this project bike died a quick death! :roll:

My 16 year old daughter has talked me out of my new KLX250. She has been wanting a new dirtbike and honestly the KLX will be perfect for her. I am once again bikeless. We have been working to remove the road equipment from the bike. She has no interest in streetriding.

Anyway, I'm leaving eveything basically the way it is. I did just install the new Cogent Dynamics shock. Very nice! Highly recommended. Rick increased the travel to between 9 & 9.5". It works great. The lights will be removed along with the headlight switch and gauges. No need for any of that now. She'll have fun with it and that's all that matters.

All the extra parts are going on being sold off.

Thanks for all the help everyone! Sorry, it didn't last longer!

SamM

dmmcd

06-06-2011, 08:07 AM

Knowing 16 y/o girls, you might be wise to hang on to those parts for when she gets tired of it in a month or two... :wink:

FastDoc

06-06-2011, 12:11 PM

And the Father Of The Year Award goes to.....

Sam!

:P

SamM

06-07-2011, 08:51 AM

Well, it comes down to the fact that I'm getting ready to buy a new vehicle and I can't just do for me and not her. The transmission in her Saturn is going. She's bummed out. She has outgrown her TT-R and she really wanted a new dirtbike. She sat on it a couple times and said, "Dad, I think I can ride this one!" Honestly, it's the perfect size for her. As it turns out, I am not very fond of the Nuetech TUbliss tubes. They make the front tire hop a good bit on the road but will be great for an off-road bike.

I'm disappointed but at the same time happy for her. This bike really is for her. She can't sell it but it's her bike to with as she pleases. The look on her face, when I gave it to her was priceless. Just like when she received her first bike. She was 7 when I gave her a new Yamaha PW50.

At this point, my KLRE will be finished soon and we'll probably start up the Diesel KLR build after that. It's not something that I want to put a bunch of money into right away but I'll keep after it. The plan is for me to build it myself. I'll farm out the frame welding but I'll do the rest.

Thanks FastDoc! She thinks so and that's all that matters. Her Mom is mad at me. Ya can't please everyone. She'll get over it soon enough. My buddies are upset with me becuase I missed a ride last Saturday. I didn't feel up to it anyway. Been a little under the weather and I'm starting to feel old.

SamM

FastDoc

06-07-2011, 11:40 AM

FastDoc understands geting older. His BD is Thursday...

Take good care of yourself. Eat and sleep well, exercise a lot. Pay attention to God. That way you'll be able to do as much as possible as long as possible. The right attitude makes all the difference too. You are right to prioritize you family.

SamM

06-07-2011, 06:28 PM

Good advice FastDoc. God is number 1 with me, then family. My health hasn't been good since they turned me into a robot. It's all good though! My BD is in a couple of months. I'll still be a couple away from the Big 50. Can't wait for that! :roll: At least my wife is young! :wink:

SamM

SpudRider

06-08-2011, 04:29 AM

Your daughter is a lucky girl, Sam! :) If you have time, please post some photos of her with her new bike!

Spud :)

SamM

06-08-2011, 05:39 PM

I'll try. She's at a church campout right now. She recently attended a Fine Arts singing competition in Baltimore, MD sponsored by the A/G Church. She placed very well and moved on to the National Fine Arts Competition in Arizona. We have a big trip to Phoenix planned for the first week of August now. She could quite possibly win a Full scholarship to college, if she places in the top 10 or so. We are hoping for more than that but the under 18 female singing category is VERY competitive.

So anyway, no new bikes for me! Dad's fronting the 3 or 4K to go to Phoenix and the Grand Canyon in a couple of months. But hey, that's my job!

Thanks for all the kind words everyone! I love this site! :wink:

SamM

Here's a picture of Caitlyn and I in a buddies Lotus Seven. I'm also hand building a 1964 Lotus Seven much like this one. She's not getting the Lotus. Not gonna happen!
http://img4.imageshack.us/img4/5208/cimg1414p.jpg

SpudRider

06-08-2011, 07:34 PM

I hope your daughter does well in the singing competition, Sam. Your daughter is not only lucky and talented, she is also quite lovely. :) Thanks for posting the great photo! We would love to follow your '64 Lotus Seven project in a new thread in our Miscellaneous Forum! ;)

Spud :)

SamM

06-08-2011, 09:43 PM

Thanks SpudRider! Thankfully, she looks like her mother!

The Lotus build is on the LocostUSA.com website. You'll have to look for it. My donor is a 1987 Ford Thunderbird Turbo Coupe. The 2.3L Lima engine has a Holset turbocharger off a Cummins Diesel pickup and makes 300hp. I call it the Death Sled. My wife hates it when I call it that. 1600lbs and 300hp is definiately a lethal combination though. The Turbo Coupe comes with a World Class T5 transmission and a posi 8.8 rear axle. It sounds like a Deuce and a Half coming up the road. I actually told my wife that I'd like to get started back on the Lotus soon. We're taking that build kinda slow. It's a long, LONG term project. Something for retirement. If I do get back into it, I'll post something here about it.

SamM

katoranger

06-08-2011, 09:57 PM

Sounds like the engine I need in my ranger. 8O

Double the weight, but still awesome.

SamM

06-09-2011, 02:18 AM

Here's my TC donor car and the 2.3L Pinto (Lima) engine. It's a New Mexico car that I picked up for $800.

http://img115.imageshack.us/img115/1879/cimg1184oq2.jpg

http://img508.imageshack.us/img508/845/cimg1179bc8.jpg

And here's what it's going into! It's a Callahan frame built in Kentucky. It's 42" across and is tiny. The wheels are 2007 Ford Mustang LX wheels with spinners. I just mounted up a set of Dunlop Direzza Sport R1 Star Spec 225/50R16 tires. I'd like to finally finish the garage and have heat in it this Winter. Too many projects, not enough time. The car will have a solid steel floor, aluminum and fiberglass body panels, a soft top and carry a fullsize spare out back on the same LX wheel.

http://img384.imageshack.us/img384/471/callahanframe008nu4.jpg

http://img17.imageshack.us/img17/1038/cimg1329.jpg

Wow, I hijacked my own thread.

Weldangrind

06-09-2011, 02:37 AM

I read about your project elsewhere; diesel bike forum maybe? Anyway, I'll be sure to follow it if it's here.

katoranger

06-09-2011, 09:21 AM

That looks just like my ranger engine. I wonder if I can just get the turbo related parts to add on. Read that I would need to install turbo pistons. 200hp would be great in the ranger. It fills like about 75 right now. Suppose to be 90, by I think some are getting a government check.

Those wheels are some of my favorites on the mustangs.

FastDoc

06-09-2011, 12:04 PM

A Turbo T-Bird transplant into a Ranger is a semi-common modification. Check out:

www.therangerstation.com

katoranger

06-09-2011, 08:25 PM

Doc, I am already looking into it. I believe that my 2.3 is probably going to need a freshening up at some point.

I really need more low end grunt. Those 800-1000lb loads of scrap metal make the hills a challenge.

SamM

05-27-2012, 02:02 PM

Hey guys,
Looks like my KLX351F project is back on. The daughter has graduated from high school and is no longer interested in my KLX. Not that she ever was. Basically, the bike has been sitting in my garage since last year. I recently added the lights back onto it and I've been riding it. Today, was my first day riding it to work. I love this little bike. This thing rips! Pictures tonight when I get home!

Stay tuned!

SamM

SpudRider

05-27-2012, 03:23 PM

That's great news, Sam! :) I'm subscribed. ;)

Spud :)

FastDoc

05-27-2012, 04:49 PM

Excellent. I do love my KLX also. I think it's an excellent all around bike that can be tailored for the dirt or the street with some basic inexpensive mods.

SamM

05-27-2012, 10:26 PM

I'm not doing that with this bike FastDoc. It still needs a few little things though. Nothing inexpensive! New side panels, the mudflap fell off, and I just found some really cool front LED turnsignals. Right now, the turnsignals are located inside the mirrors. They are a bit odd and I don't like them very much. It also has new Zeta breakaway pivot hand levers. The TUbliss tubes are bouncy on the street. I may ditch them too. I have a set of Heidenau K60 tires in my shop. Regular tubes and those tires should work well on the street and off-road. The 3 gallon IMS tank is at my dealer's place. I'll pick it up Tuesday morning and hopefully get it mounted that same day.

The bike is coming together nicely. The 351cc kit will have to wait until Winter arrives. I plan to port the head and install a Mikuni 34mm carb and KLX300R cams, when I install the engine kit.

Thanks for looking!

SamM

http://img706.imageshack.us/img706/788/cimg0654qx.jpg

http://img94.imageshack.us/img94/8719/cimg0653d.jpg

SpudRider

05-27-2012, 10:53 PM

I've forgotten. What's that fine looking bike in the background, Sam? ;)

Spud :)

SamM

05-27-2012, 11:03 PM

It's a 1998 Honda Shadow. That's the bike that Harley-Davidson sued Honda over. It has a single crankpin just like the Harley engines. I believe this was the one and only year for that particular bike. Honda was forced to change it.

This one belongs to one of the guys that I work with. It was his father's bike and his sister recently gave it to him.

SamM

FastDoc

05-28-2012, 12:47 AM

Love that bike.

How do you like the exhaust? Is it very loud? I'll be interested in your feedback on the fuel tank. Does it use the stock shrouds?

SamM

05-28-2012, 09:56 AM

The FMF header and muffler are not loud at all. The header actually gives the bike a 3 dB lower exhaust tone than stock. I'm sure the muffler raises that but it's not loud.

Yes, the IMS tank uses the stock KLX shrouds. I hope to have it installed tomorrow. 3 gallons doesn't sound like much but this bike sips fuel, at least for now! Once I add the big bore kit all bets are off on that.

The next big project is balancing the wheels and swapping the tires for the Heidenau K60s. I also need to get the speedo working. The SF sending unit does not work with the 21" front wheel. 12 O'clock Labs has a differential circuit board but it costs $80. It pigtails into the speedo wiring. I need to check to see what the KLX250S sending unit is before I jump into that. If the S sending unit is less I may go that route. The bike does have a 12 O'clock Labs rear taillight circuit board in the DRG LED taillight. The integrated turnsignals are very nice and there is nothing to break off the back. It's a clean look out back and I like that. Worth the coin! I installed a locking rear license plate holder. I keep a little cash and all my paperwork in that. The rear tailpack holds my tools and a Moose Racing tire patch kit.

The rear rack is very small and I may end up ditching it and going for a cyclerack.com rear rack.

This bike really is the perfect size for just about anything you throw at it. She's not the greatest at highway touring, especially with the TUbliss system in the wheels but I'll work that out soon. Heavier tires and some wheel weights should help. The 250cc engine's power is pretty good stock and the bike is very flickable as is. I recently took it on a poker run type ride. I was the safety bike and blocked oncoming traffic at the intersections. I was easily able to get back to the front of the pack once the other riders figured out what we were doing.

I can't wait to get the 351 kit installed. It will be a beast. I'm shooting for at least 30hp out of it.

SamM