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Blood Sweat Tears and Grease => Projects => Enduro / Dirt / Scramblers => Topic started by: The Jimbonaut on Jan 26, 2018, 15:02:09

Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 15:02:09
Another November in Montreal means another 5 or so months of riding absolutely nowhere fast.  It does mean however that the $$ I made from selling my Sportster opened the door to some more-than-speculative evenings on kijiji, where I shnaffled up this '00 KLR650C (yes, it's the C model, more on that later) -

(https://i.imgur.com/K2vfz6Y.jpg)

13,000 kms on the clock (all off-road - this bike had never seen legal asphalt), several un-careful owners (goes with the territory) and now mine. 

Before I go any further I want to post this and see if damn Imgur works.  Holy shit photobucket, you and your very frustrating interface just shaved days off my life expectancy. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 15:15:16
Tidy.  Hello Imgur, fuck you forever photobucket.  Ok, onwards.

From the test ride it was clear this thing had a few issues.  None of which I was warned about.  So the fact it had no rear brake whatsoever and very limited front meant the fence at the bottom of the hill arrived quickly and in a manner most unforgiving.  It was also pissing gas all over my jeans, spraying oil out of the forks and making a weird noise out of the exhaust.  Nothing however too major hopefully, and all good in terms of bargaining chips.  Ended up shelling out $950 US for it, and promised the missus the smell of old gas in the car on the drive home would dissipate eventually.

Home -

(https://i.imgur.com/DREYsf5.jpg)
(https://i.imgur.com/28Fs65K.jpg)

Hope Rhonda approves.  They'll be spending some quality time together.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Jan 26, 2018, 15:25:11
Looks pretty clean. I'm in
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 15:27:27
It's very green (which I dig) and very purple (which I dig less).  Reminds me of an 80's skiing outfit my Mum was very proud of.  Not sure how it's gonna end up after I've put my stink on it but we'll see, have a few ideas percolating.  I do however love the look of the C model.  No offence to KLR guys but the regular A model (and later E model) is not my favourite looking dual sport - truth be told they're a class of bike built for what they can do rather than how good they look doing it.  As far as these larger 650's are concerned - and in my very subjective opinion - this C model is the looker of the bunch.  It's more dirt-oriented than the A model with better suspension and brakes, and with a tank that doesn't look like a camel with elephantiasis of the hump.  Good looking fairings and an absolute blast to ride.

Had to overhaul the front and rear callipers and rebuild the rear master cylinder completely.  Anyone who followed the Rhonda thread will know I'm totally winging it - everything I do is a first.  This build will be no different.  And so it was with the rear master cylinder.  Took fucking forever until I realized one washer was on the wrong way round - after days of learning new swear words finally got the thing to pump some fluid.  Front calliper no problem, ditto fork seals.  New Shinko rubber too, and a new petcock so I no longer wear the gas, I burn it.  Better.  Slung on some reflective stickers and passed the safety inspection needed here in Quebec to plate the bike for road use.

Armed with official legitimacy, could now start tearing it all apart -

(https://i.imgur.com/lZrpDOY.jpg)

and really starting to dig the look of the bones of this thing -

(https://i.imgur.com/IDigOxd.jpg)

The plan is to really get into the engine (never done anything like that before apart from checking valve clearances) so this'll be an adventure.

(https://i.imgur.com/a2dV2XN.jpg)

Smells like...victory
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 15:43:10
Tell you what, getting a single-cylindered thumper engine onto the workbench is a helluva lot easier than an inline four.  I'm happy, my osteopath will have to scalp some other poor victim.

Carb hero shot -

(https://i.imgur.com/fAaHeIG.jpg)

One of the handlebar clamp bolts sheared off in the triple tree which sucked balls, and the kickstand bracket on the frame was so bent that it meant the bolt wasn't moving for love or money and I couldn't remove the kickstand.  Once everything else was off the frame I hauled it to my guy here in Montreal who removed both and helicoiled the triple tree so a new bolt can later be installed.  Which was a very good thing.  Turns out the C model was never sold in the US and is rare as hen's teeth here in Canada - finding replacement parts is not easy.  Glad we could salvage the triple tree otherwise, well, bollocks.

Valve cover removed and everything looks as it should in there, 2 overhead cams, 4 valves, no signs of oil starvation or grim-reaper style engine wear...

(https://i.imgur.com/7mGt3pF.jpg)

Clymers held my hand as the cams came out...

(https://i.imgur.com/sfWpnoa.jpg)

...and assured me the cylinder was not beyond me either.  $10 Breaker bar from Canadian Tire turned out to be the best ten bucks I'd spent in a while.  Head bolts out -

(https://i.imgur.com/Zl0Y3mq.jpg)

and cylinder off (after a few love taps with a rubber mallet) -

(https://i.imgur.com/eLrbFAj.jpg)

Removed the stock piston

(https://i.imgur.com/Me3DSey.jpg)

as I'll be replacing it with a 685cc Wossner piston and boring out the cylinder.  See?  Sounds like I really know what I'm talking about.  I don't though.

Piston removed -

(https://i.imgur.com/jo77bJC.jpg)

And this lovely lady for no other reason than sheís a lot prettier than my workbench -

(https://i.imgur.com/zmzhV7E.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 16:00:59
Using my fingernail to clean off all the carbon shit from the piston.  Not the worst idea ever, but far from the best.

(https://i.imgur.com/3rsSFP6.jpg)

Anyway, the things grow back.  I'll be using the piston as a cigar ashtray.  I've always wanted one.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 16:16:49
Ok, doohickey time.  Anyone that owns a KLR (at least the older models) knows - or should know - about the doohickey.  It's a pie-slice-shaped lever on the balancer chain.  There's a engine casing mounted spring that keeps tension on the lever, and therefore tension on the chain.  However the stock spring and lever are universally considered to be utter shit and for good reason - they always fail.  There's a guy called Eagle Mike who's the guy for all things KLR, and he makes the go-to doohickey replacement lever and spring.  When I bought the bike I asked the PO if the doohickey had been replaced and he looked at me like I was talking Russian, so figured it probably hadn't.  Turned out, I was right -

(https://i.imgur.com/Oxnbfx4.jpg)

See that spring at the bottom of the pic with the broken end?  That's what you don't want to see.  At least the lever was still in one piece, and only a small part of the spring had gone for a ramble inside the engine casing.  Anyway, to get to it you need some special tools (which I borrowed) and a few beers.  Here's a shot of the new lever installed along with the far superior torsion spring -

(https://i.imgur.com/anqvJGz.jpg)

Thankfully anyone needing to do this procedure on their KLR has a wealth of vids and walkthru's online - it's literally a mod that any KLR owner needs to consider.  There's a groove already machined into the lever for the torsion spring to sit in, but I had to dremel out the groove further in order for it to seat.  Parts cost about $60 I think.  Gotta be done.

During the process I learnt what a woodruff key is.  A woodruff key is this little mite -

(https://i.imgur.com/7A8bWLP.jpg)

and sits in the crank to stop the rotor and starter gear from de-locating.  So there you go.  Done the doohickey.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 16:30:54
Next job was to see if I could track down the snapped off piece of spring.  Should have fished around in the oil pan with a flexible magnet but a flexible magnet I did not have.  Time to crack open the other side of the engine then.  Off comes the water pump, impeller and seals -

(https://i.imgur.com/w25M1oI.jpg)

and then the side engine casing -

(https://i.imgur.com/uy8JaUV.jpg)

No sign of the broken spring part in the oil strainer so it's either come out in a previous oil change (best case scenario) or doing laps of my crankcase -

(https://i.imgur.com/iuNf0MB.jpg)

- but what looks to be a smashed up oil seal in there so that gives pause for thought.  Took the oil pump apart to check for signs of wear -

(https://i.imgur.com/pI6MYjP.jpg)

- and all seems well in its little world so I'll be leaving well enough alone.  New gaskets and buttoned it all back up.  Phone rang, cylinder's ready from the the machine shop so picked it up along with my new Wossner piston.  It's really light compared to stock, and considerably prettier.  Apparently I'll get a bit more horsepower and a bit more torque with less engine vibration to boot, plus the whole process had been a great learning curve too.  Here's a comparison shot -

(https://i.imgur.com/VaOV3cB.jpg)

Piston installed without too much drama -

(https://i.imgur.com/7E4Dnxd.jpg)

And that pretty much brings us up to speed.  Cylinder is eating to be installed, covered in flash rust that hopefully WD 40 will knock off.





Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 26, 2018, 16:31:57
Cylinder is absolutely not eating anything.  Waiting.  It's waiting.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Limey on Jan 26, 2018, 18:31:26
I like the big KLR, a trailie for hairy chested meat eating chick loving men.  I am definitely in!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on Jan 26, 2018, 19:47:24
Ah yes.  Big bore thumpers for the win. Following along. Love it

Sent from my SM-G920V using Tapatalk

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: JustinLonghorn on Jan 26, 2018, 21:57:27
I'm on board.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: doc_rot on Jan 26, 2018, 22:55:38
Cool project. I usually drop the oil pan on new(to me) bikes to see what tales it has to tell, gives you an opportunity to clean the sludge out and look for your missing spring piece.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Jan 27, 2018, 12:42:00
I think i saw that missing piece of spring still sitting in its recession in the casing, right there in the picture. Covered with a bit of oil.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Jan 27, 2018, 15:37:21
Nice project, I like the frame on this girl, will this be a restoration or a mod or in between?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 29, 2018, 12:30:07
I think i saw that missing piece of spring still sitting in its recession in the casing, right there in the picture. Covered with a bit of oil.

I wish.  Trick of the light sadly - hooked part of the spring is definitely MIA.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 29, 2018, 12:36:55
Nice project, I like the frame on this girl, will this be a restoration or a mod or in between?

Think I'm going the resto-mod route.  I like the fairings and look of this C model too much to bin too much of it, so I'm going to do a bunch of upgrades to the bike, learn a bit, and maybe go balls out on an air-cooled thumper for my next build.  This KLR has a honking great radiator and coolant reservoir up front which would really stretch my limited skills to replace/relocate - thinking an air-cooled engine will look cleaner once I sling the fairings.

The purple tank is incredibly purple however and the rear fender could use a clean up.  Kinda winging it as I go along but have a few ideas shaping up.   
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 29, 2018, 12:44:39
After a call to Wossner to order a new, oversized head gasket I learnt that I'd totally fucked up the piston ring gap.  I'd gapped the new Wossner rings based on the Clymers OEM specs and luckily the very helpful bloke on the phone gave me the correct specs for their rings.  I was halfway through a (unrealized) very strong IPA at the time which I'm blaming for then over-filing the ring -

(https://i.imgur.com/goEv91O.jpg)

Only went over by 0.1mm and after another call to Wossner was assured that as it was the second, oil scraping ring that I should be ok.  Cool, back to the IPA.  This stuff'll put hair on your eyeballs -

(https://i.imgur.com/8TIpcU1.jpg)

- but goes down extremely well.  Apt name too.  Just replace "Universe" for "piston rings".

Cleaned up all the frame and gubbins ready for powdercoat -

(https://i.imgur.com/FjpS0cD.jpg)

- and I'm off to the races.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Jan 29, 2018, 13:09:06
I wish.  Trick of the light sadly - hooked part of the spring is definitely MIA.
Tell me i at least made you go and look again  its probably ground up to a fine powder or pressed into a gear cog by now anyway!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Jan 29, 2018, 13:22:16
Signing up. I'll let you know when I get your gasket kit out of Maine for you!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 29, 2018, 13:27:25
Tell me i at least made you go and look again  its probably ground up to a fine powder or pressed into a gear cog by now anyway!

You definitely got me thinking about it!  I've already replaced all the gaskets etc and just couldn't bring myself to tear into them again so I'm just going to pretend you didn't say anything and convince myself that it was, indeed, a trick of the light.

It's only half-working.

Damn you.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 29, 2018, 13:31:23
Signing up. I'll let you know when I get your gasket kit out of Maine for you!

Legend.  Cheers Mike  8)

I was going to try dremel-ing out the stock head gasket I have to enlarge it to the new bore size, but figured that plan was ripe with disaster.  We're talking 1mm off the entire circumference and for the dough I've shelled out on the piston and cylinder bore then a couple of bucks on the proper fitting gasket just made sense.  I'll try and bodge another job on the list, but this one felt like getting it done right.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 29, 2018, 14:55:02
Consider this -

A society's intelligence and level of advancement can be measured by how much of its star's energy it stores and uses.  To whit, the Kardashev Scale was developed to determine this measurement as follows -

Type One - A civilization that harnesses and uses all of the energy that falls on its planet from its solar system's star
Type Two - A civilization that harnesses and uses all of the energy that radiates from its solar system's star
Type Three - A civilization that harnesses and uses all of the energy created by its fucking galaxy

Earth, and us rabble on it, store and use about 1% of the sunlight that lands on our planet.  So we're a long, long way off becoming a Type One civilization.  And that kind of explains a lot.  Interstellar space travel is still a pipe dream for us, and we still can't figure out how to fix pot holes once and for all.  Space faring civilizations would need some serious rpm's to break free of the fossil-fuel confines that us humans find ourselves shackled by, and getting a load more wattage out of the parent star would go some way towards explaining how they tame the mysteries of serious interstellar road trips.   

So anyway, a bunch of astronomers were doing their thing, looking up into the sky with their telescopes when they found something pretty fucked up.  Apparently the way they look for solar systems with potentially habitable planets is by studying the light emitted from the system's parent star and looking for dips in the light emitted from the star - caused by a planet orbiting in front of it.  These solar systems are literally thousands and thousands of light years away - they can't "see" the stars or planets but they can figure out a lot of shit about them by looking at the telemetry from these observations.  Dip in light, good indicator of a planet orbiting the star.

These dips in light can be studied remarkably accurately, so I'm told.  Importantly, they can also be used to ascertain the shape of the object moving in front of the star as well.  A regular, spherical-shaped object (like a planet for example) leaves a very smooth signature in the telemetry.

So, back to the astronomers.  They were looking at this one particular star, called KIC 8462852, and discovered that whilst the light emitted from the star was indeed dipping (indicating something moving in front of it), these dips were highly irregular in both shape and spacing.  Planets were ruled out, as were comets and dust clouds - something weird was moving in front of the star, but they were hesitant to say what.

And then someone had a proposition - the astronomers had found the first recorded evidence of a Type Two civilization (a civilization that harnesses and uses all of the energy that radiates from its solar system's star), in the form of a Dyson Sphere.  A Dyson Sphere is a shell or matrix constructed to enclose a star and farm all of the light emitted from it.  The constructs are unfathomably huge, and constructed - hypothetically - by self-replicating robots using materials mined from nearby planets.  To give an idea of scale, the smallest of the "panels" used in the sphere's construction would have an edge length one hundred times the distance between the earth and the moon, or 38 million kilometres.  Not insignificant.

Therefore, if the Dyson Sphere was still under construction there would be many irregular gaps as it rotated around the star, and the telemetry we receive here on Planet Earth would translate this as irregular dips in the light emitted from the star.


It's enough to get you thinking on a Monday morning.


Anyway, I'm going to start a Dyson Sphere build thread after this.  Fuck it.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Jan 29, 2018, 16:32:56
Very cool!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 30, 2018, 10:46:49
Mucking about on photoshop last night trying to come up with a colour scheme -

(https://i.imgur.com/XGIoSlw.jpg)

Thinking a satin black frame with a satin silver swingarm (black in the photo above).  Need to find some OEM green side covers but they're totally unobtanium so may have to go the vinyl wrap route on them instead.  Brushed steel tank with a 2K clear, and some brushed stainless steel panels and trim that I'll - ahem - "fabricate".  I have to use that word reservedly - most of you guys are fabricating triple trees and entire bike frames.  I'm the Great Pretender.

A big job on this rebuild is going to be restoring the plastics.  They're mostly very faded, but in the areas where the elements haven't got to them (under the headlight fairing for example) the colour looks so good that I really want to get my green on.  Watched a few vids and seems the best (if most time consuming) method is with various grades of sandpaper and soapy water.

It'll need new fork boots and a few other odds and sodds, but Version One is in the bag.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Jan 30, 2018, 11:08:59
Needs more PURPLE!  ;)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 30, 2018, 11:26:45
Needs more PURPLE!  ;)

Sounds like something my ex-girlfriend would say!  She'd paint the world purple given a paintbrush and half a chance.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: canyoncarver on Jan 30, 2018, 16:38:13
Nice pics on the doohicky mod.  I don't have a KLR but I've heard of the fix.  I want one.  You were right about the C model.   It looks more sleek than most.  Pretty cool.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 30, 2018, 23:37:33
Dropped off the frame etc and totally changed my mind at the last minute. Satin silver, not satin black. Weíll see how that works out.




Sent from my iPhone using DO THE TON
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 31, 2018, 00:05:15
Nice pics on the doohicky mod.  I don't have a KLR but I've heard of the fix.  I want one.  You were right about the C model.   It looks more sleek than most.  Pretty cool.

Make it happen mate, these bikes are brilliant.


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Mr.E on Jan 31, 2018, 00:20:09
I'll watch too, this'll be fun
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on Jan 31, 2018, 00:33:26
I'll watch too, this'll be fun
There are the big three jap 650 thumpers (klr,  Dr, and xl) going on here right now. Well yours is a 600, but it's ok, it's really trying :)

Oh and Eric's German Canadian thing-a-ma-bob.  ;)

I like it

Sent from my SM-G920V using Tapatalk

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Jan 31, 2018, 02:03:48
There are the big three jap 650 thumpers (klr,  Dr, and xl) going on here right now. Well yours is a 600, but it's ok, it's really trying :)

Oh and Eric's German Canadian thing-a-ma-bob.  ;)

I like it

Sent from my SM-G920V using Tapatalk

Does that mean I have a little jap thumper?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 31, 2018, 10:47:24
Bought a new Rigid toolbox yesterday (fairly confident I could drop that thing off a mountain and it'd scoff up at me from the bottom asking if that's all I got) along with a decent drill - I need to drill through the frame and subframe to strengthen the thing up as the stock bolts are known to fail. 

One thing I'm not especially looking forward to is cleaning out all the gunk from inside the tank.  There's rust in there but that's not the worst of it - there's this kind of solidified pale sludge (not varnish) that's got me thinking it's time to wheel out the big guns - namely the methyl ethyl ketone, or MEK.  That shit's unruly - I used it on the CB tank to get the varnish out and whoa nelly did it get the varnish out.  It also melted an eyeball and I now dribble at the dinner table.  Full respiration mask is de rigueur with this stuff - it does not mess around.  So, that's today's job.  First need to make some rubber bungs to block up the petcock holes. 

Theme song for the day - Jambi by Tool.  Have at it.   
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 31, 2018, 11:12:24
^^^ Edited to mention - it's not really a decent drill at all, it was the cheapest Home Depot had.  But it has adjustable speed which my other drill doesn't (which was even cheaper.  That thing's so damn fast if it snags I do an impressive if rather dramatic impression of a cartoon whirlwind)

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Jan 31, 2018, 17:41:58
If everyone else is joining in, I might as well too.  Also, Tim has it set up for DTT to host images.  No need for Imgur, Photobucket or anyone else.  See: Gallery.  And if you use your phone to post, then you can put the images right into the body of the post.  No need to separately upload and link.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: canyoncarver on Jan 31, 2018, 17:56:10
If everyone else is joining in, I might as well too.  Also, Tim has it set up for DTT to host images.  No need for Imgur, Photobucket or anyone else.  See: Gallery.  And if you use your phone to post, then you can put the images right into the body of the post.  No need to separately upload and link.

I second this one.  Using an external image site for posting is gonna bite your ass sooner or later. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jan 31, 2018, 19:58:31
Welcome aboard gents - would love to reassure you that you wonít regret it but quite frankly all bets are off.

Spent a good portion of the afternoon congratulating myself on how brilliant I was for carving a rubber bung out of some flooring mat. Then poured the methyl ethyl ketone into the tank and immediately found out the hard way that my rubber bung was for shit.

It was a bad scene.

Garage looked like a messed up version of Breaking Bad - me in a respirator mask mopping up a chemical that literally melts eyeballs.

Thanks for the photo tip - Iíll check out Gallery as soon as my eyes have stopped bleeding.




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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 01, 2018, 14:11:40
So, MEK.

Itís the Louis Cypher of chemicals. Substitute Robert De Niro in Angelheart for 4 litres of methyl ethyl ketone, slowly un-peeling a hard boiled egg while referring to it as a human soul and you get the idea what this stuff is capable of.

I ended up pouring it all over my shoes, chair and garage floor while trying to decant it out of my tank and into a water bottle. Thank fuck for snow - shovelled a load into the garage to mop up the spill and have my shoes buried in a snow bank.

Would I recommend this stuff?

Absolutely. Itís hhahgdnnejnnd x xnnsnznnxnfjejijeurjbfbdbsnsjaksbgggggggggggggggghhjjjjjjjhhhhhhhhhhhhhh


Sent from my iPhone using DO THE TON
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Feb 01, 2018, 17:03:07
You gonna make it Jimbo? :o
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Feb 01, 2018, 17:28:22
Really enjoy your sense of humour as well as your builds :)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 01, 2018, 20:47:46
You gonna make it Jimbo? :o

Oh I'll be fine.  Hallucinating a little, but the sordid collection of little sparkly winged objects will rue the fucking day as soon as they stop flying around in my field of vision long enough for me to swat them.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 01, 2018, 21:02:20
So the bung was a complete and utter fail, as was the large majority of the MEK episode.  I'd like to think I learnt something from the woeful experience but pretty sure if the stuff ever darkens my door again things will go just as sideways.

Moving on.  Next step in the tank cleanup means getting the rust out.  Reeled out a few yards of chain into the tank to knock off as much of the large stuff as possible.  Then it was time for the big guns.  Frank from American Pickers, take a bow -

(https://i.imgur.com/ybk9UmW.jpg)

Armed with his cheery good temperament I dumped two jugs of his finest into the tank, but not before addressing the bung situation.  Petcock has two bolt holes and one long pill-shaped hole in the tank.  So I chopped up some steel, beaded out some gasket sealer and voila -

(https://i.imgur.com/655jeBW.jpg)

Sealed.  Metal Rescue doing its thing in the tank, and I'm having a beer.


Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 03, 2018, 21:40:03
Tank cleaned up great.  That Metal Rescue has one job to do and it does it with aplomb.  Gave the thing a rinse out, got the wife's blow drier in there and once the inside was hot and dry as Gandhi's flip flop I swilled some WD 40 around.  Job's a good'un.

Now the fun part.  Goodbye purple...

(https://i.imgur.com/b6kOZ7A.jpg)

and hello brushed steel -

(https://i.imgur.com/a5RpUVY.jpg)

Trying to work with the lines of the fairing so it's slow going on the sanding, but liking how it's starting out. 

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on Feb 03, 2018, 22:15:27
Tank cleaned up great.  That Metal Rescue has one job to do and it does it with aplomb.  Gave the thing a rinse out, got the wife's blow drier in there and once the inside was hot and dry as Gandhi's flip flop I swilled some WD 40 around.  Job's a good'un.

Now the fun part.  Goodbye purple...

(https://i.imgur.com/b6kOZ7A.jpg)

and hello brushed steel -

(https://i.imgur.com/a5RpUVY.jpg)

Trying to work with the lines of the fairing so it's slow going on the sanding, but liking how it's starting out.
Keep it bare metal to match your 7fifdy;)

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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 03, 2018, 22:32:54
That's the plan mate - I'll hit this with gloss 2K instead of satin this time.  Also going to be making some stainless steel panels for the side fairings and fenders, and going to attempt restoring all the plastics too.  It's an inhuman ball-ache so I'm told - a lot of time and a lot of sanding - but this green is too good to pass up.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 03, 2018, 22:34:39
Maybe something like this -

(https://i.imgur.com/y3RQIwF.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Feb 04, 2018, 08:13:13
I like that!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Tim on Feb 04, 2018, 11:12:37
I like the silver tank - either painted or brushed/clear coated.

But I'd skip the stainless steel panels on the plastic.  First, I like them plain green without decals.  You can always get vinyl cut if you want to add accents to them.

The thought of stainless steel razor-thin sheets of stainless steel in my way as I get dumped off the bike isn't appealing.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 04, 2018, 11:31:47
You're not wrong Tim, that's a frightening thought.  I've got a few ideas on how I can try to flush the panels with the fairings but I've never tried metal-shaping before.  The panels would need to be contoured perfectly - then I'd run a bead of silicon around the edges and bolt them down.  Idea being the silicon would form something of a buffer all around the edges of the panels.  Kinda hard to explain but it works in my head.  Mind you, so does quantum theory - but I'm blagging that as well.

The vinyl is a good idea - I've looked for some "brushed steel" vinyl and 3M make a decent wrap.  Think I can get die cut vinyl panels made?  Something to look into.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Feb 04, 2018, 12:27:25
You're not wrong Tim, that's a frightening thought.  I've got a few ideas on how I can try to flush the panels with the fairings but I've never tried metal-shaping before.  The panels would need to be contoured perfectly - then I'd run a bead of silicon around the edges and bolt them down.  Idea being the silicon would form something of a buffer all around the edges of the panels.  Kinda hard to explain but it works in my head.  Mind you, so does quantum theory - but I'm blagging that as well.

The vinyl is a good idea - I've looked for some "brushed steel" vinyl and 3M make a decent wrap.  Think I can get die cut vinyl panels made?  Something to look into.
Heat up the ss bits with a torch and press them onto the panels, they'll hotglue themselves solid on there!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 04, 2018, 12:35:34
Heat up the ss bits with a torch and press them onto the panels, they'll hotglue themselves solid on there!

Good plan, until they fly off and turn into 140kmph ninja stars on the highway...shudder... :o
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Feb 04, 2018, 12:53:06
Good plan, until they fly off and turn into 140kmph ninja stars on the highway...shudder... :o
Sounds great!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: doc_rot on Feb 07, 2018, 05:04:01
You're not wrong Tim, that's a frightening thought.  I've got a few ideas on how I can try to flush the panels with the fairings but I've never tried metal-shaping before.  The panels would need to be contoured perfectly - then I'd run a bead of silicon around the edges and bolt them down.  Idea being the silicon would form something of a buffer all around the edges of the panels.  Kinda hard to explain but it works in my head.  Mind you, so does quantum theory - but I'm blagging that as well.

The vinyl is a good idea - I've looked for some "brushed steel" vinyl and 3M make a decent wrap.  Think I can get die cut vinyl panels made?  Something to look into.

IMHO faux brushed steel panels are akin to "bullet hole" stickers, you aint fooling nobody, and it just looks tacky. If you want the brushed metal on the plastic make them out of metal, but don't fake it.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Feb 07, 2018, 09:51:29
From an Avery swatch book I have in the office.  Pretty cool stuff.

Hit me up if you need decals I can make it happen
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 07, 2018, 10:30:55
Thanks man, those look pretty slick.  I ordered some samples from 3M of their brushed steel and brushed aluminium just to get an idea of what they look like.  I don't have much experience with vinyl wrap (I wrapped a gas tank - or tried to - which didn't end so well) but it could be a good option if the stainless panels I'm hoping to make don't work out. 

That's very cool that you can help with the decals mate - I may well take you up on that.  Once I've played around with some ideas maybe I'll send some your way and you can give me a quote?  Muchas gracias =)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Feb 07, 2018, 11:33:09
Yessir. I was looking for 3M swatches but I donít have a book for their specialty vinyls for some reason. Avery is kinda shite IMO but just an example


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 07, 2018, 13:30:37
Cool cool - I'll see what the 3M samples look like and I'll give you the heads up mate.  Just got back from checking out my powdercoat sample - too grey with no metallic but no drama.  It was only a sample so they're gonna match up the paint and hit it again.  Also stopped in to say hi to a guy down that way who restores old Japanese bikes, man he's got it going on.  Four '70's KZ900's in perfect shape as soon as I walked in the door, and a CBX upstairs that was just breathtaking.  And an RV125 up on the table, looking superfine.

I asked him about an air pump for yours and he thinks he has an original one knocking about somewhere. I told him if he could find it to let me know what he wants for it - I'll let you know what he says.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Feb 07, 2018, 14:13:57
I asked him about an air pump for yours and he thinks he has an original one knocking about somewhere. I told him if he could find it to let me know what he wants for it - I'll let you know what he says.

That would be boss mate, good looking out. If you talk to him again, I also need the sprocket cover that bolts on the engine - its proving elusive.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 07, 2018, 14:22:47
Consider it done - I'll be down there again in a few days so I'll ask him, no worries  8)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 08, 2018, 10:13:35
Still working on sanding the tank - hopefully today the OCD in me will give way to the call-it-good.  Also will be rebuilding the carb with the new Harley slide and diaphragm which is  - surprisingly - a much cheaper option than the Kawasaki part (earlier model KLR's use the same CVK40 Keihin carb as the Sportster), and also with a new DynoJet kit.  I'll be modifying the airbox and have a new exhaust system on order - Stage Two jetting all the way.

We had some snow in Montreal yesterday, had to dig my way into the garage...

(https://i.imgur.com/No5Ad8u.jpg)

So too did the UK.  My Dad sent me this extreme weather photo -

(https://i.imgur.com/tegUHZe.jpg)

That spells havoc in England.  More than enough snow to ground all flights in and out of Heathrow, and - according to my Dad - to "cancel all Brexit plans".  It's dramatic stuff.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Feb 08, 2018, 16:49:56
 :)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Limey on Feb 10, 2018, 07:08:16
Problem with Heathrow is its at capacity.  A plane lands, and immediately there's another taking the slot to follow it in, and vice versa taking off.  The slightest delay means the system collapses, and the only way to keep it running is to lessen the number of flights.

Aside from that, he's right.  My countrymen are a bunch of lightweight commie cuddling vegetarians.  A flake of snow and the world grinds to a halt because they're idiots.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 10, 2018, 10:58:44
Problem with Heathrow is its at capacity.  A plane lands, and immediately there's another taking the slot to follow it in, and vice versa taking off.  The slightest delay means the system collapses, and the only way to keep it running is to lessen the number of flights.

Aside from that, he's right.  My countrymen are a bunch of lightweight commie cuddling vegetarians.  A flake of snow and the world grinds to a halt because they're idiots.

My Mum can certainly attest to that - she lives right under Heahrow's flightpath.  Depending on whether the flights are landing or taking off, there's a plane flying over her juniper bushes every 3 minutes in the summer.  Heard they're still arguing over whether or not to build another runway - doing so would make sense but apparently means bulldozing an entire town or five.  Guess the whole "good idea" thing depends on perspective and geography...

By the way, great avatar mate.  RIP Kenny - it was all done in the best possible taste
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 12, 2018, 12:41:36
While I'm waiting on a couple of bits and pieces to arrive I've been trying to restore the plastics.  Pretty faded after 18 years of sitting out in the Canadian wilderness and in need of a bit of attention.  I've learnt from my good friend youtube that the best way to get them back to decent condition is to sand the shit out of them - 320, 400, 600, 1200 and then polish.  The sanding is an inhuman ballache but I can definitely see good results after several hours of elbow grease - the faded parts on the rear fender that I've been working on now look close to the original colour, but for love or money I can't get them to polish up - they stay dull. 

Ghetto polishing FTW -

(https://i.imgur.com/Pwqg6g6.jpg)

Think maybe the problem may be -

1. drill not spinning fast enough
2. buffing pad is for shit
3. not using the right polishing compound (I'm using Maguires Ultimate Compound and/or Nu Finish Once A Year Polish)
4. I'm not using any water when I'm polishing

Anyone got any tips on how to get this job done without me further losing my will to live?

 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 12, 2018, 13:23:09
I got a box with a fancy muffler and head gasket in my car to ship you this afternoon ;D 

you can try this:  http://www.canadiantire.ca/en/pdp/simoniz-headlight-restoration-kit-0391063p.html#srp

I have used the headlight polish to shine up old dull plastic, not just lenses. It also adds UV protection, or at least the Plastix brand one I have does.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Feb 12, 2018, 16:09:05
I got a box with a fancy muffler and head gasket in my car to ship you this afternoon ;D 

you can try this:  http://www.canadiantire.ca/en/pdp/simoniz-headlight-restoration-kit-0391063p.html#srp

I have used the headlight polish to shine up old dull plastic, not just lenses. It also adds UV protection, or at least the Plastix brand one I have does.

That's good to know.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 12, 2018, 16:11:11
That's good to know.

That is after the 600/1000/1500/2000 grit wet sand session.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Feb 12, 2018, 23:57:36
That is after the 600/1000/1500/2000 grit wet sand session.

Gotcha!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 15, 2018, 11:08:43
Thanks in no small part to Mr Maritime (thanks again mate) a care package arrived a couple of days ago -

(https://i.imgur.com/HNMjen7.jpg?1)

New Lexx can with mid pipe (not supposed to fit on my C model but I'm hoping with some stubborn will and questionable fabrication skills I can make it happen) and 3 ply head gaskets.  The Lexx exhaust is the in-house brand from Rocky Mountain ATV - not available here in the Great White North - but the reviews look good and for $200 it's less than half the price of FMF, Two Brothers, Yoshimura etc.  The stock can on these KLR's can develop a "tweety" sound which mine most definitely had, which sounds every bit as bad as the name suggests.  Fine for a little yellow cartoon bird, lame on a 650cc dirt-chomping hooligan.  Plus it's ugly as blind cobbler's thumb.  Looking forward to installing the thing and seeing what gives.  That'll be for another day however.

With the new gaskets in hand I installed the new, bored-out cylinder -

(https://i.imgur.com/9mbluqD.jpg)

- and discovered it's a tricky thing to compress the rings while lowering the jug.  Well, maybe not tricky but certainly there's a knack to it.  After several attempts - and making sure I had the spacing correct on the rings - finally got it lowered with a triumphant holler of success -

(https://i.imgur.com/HkOhLaA.jpg)

That new Wossner piston is sitting in there very prettily indeed I must say.  It's shape is going to fill the combustion chamber way more than the stock piston, it's way lighter too.  Time will tell how much extra boom I get out of the thing.

Great learning curve - it's all doable with beer.  Needed to down tools at that point and make my daily Canadian Tire trip to pick up some crow foot sockets - there are a couple of acorn nuts on the jug that need to be torqued down but access to them is limited.  Got the sockets. Got them torqued.

Poured thinners into the head - no leaks through either the intake or exhaust valves.  Sweet.  I'll give them a clean and will be getting the head on later today with the help of my mate's 10 year old son.  We've been building all manner of madness with his computer game Besiege the last few days - today it's time to get his hands dirty with the real thing.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 15, 2018, 11:46:16
When you have the cylinder off of your next engine, consider putting a slight chamfer on the bottom inner edge, makes it loads easier to slide it all back together. Just donít forget to wash it well after unless you want that slick bore job looking like Betty Whites backside.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 15, 2018, 11:53:25
Just donít forget to wash it well after unless you want that slick bore job looking like Betty Whites backside.


Sent from my iPhone using Tapatalk

Now there's an image to curdle my cornflakes.

The cylinder on the KLR has a chamfer on the inside edge, but as this is the first engine I've rebuilt to this extent I just assumed that all cylinders did. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 15, 2018, 12:04:25
Most do, usually with a bit of lube and a little love tap everything just kinda pops in.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 15, 2018, 13:44:25
Looking good, hope the more bang isn't the big bang of the piston grenading LOL.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 15, 2018, 21:23:51
Pistons grenading, Christ, is that a thing?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 15, 2018, 22:55:13
(https://uploads.tapatalk-cdn.com/20180216/f1ad241c0b8e0d27b229b7eec4c75dd0.jpg)
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 15, 2018, 23:20:57
Is that a piston or an overcooked marshmallow? That looks frankly awful.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 16, 2018, 08:34:04
Run lean long enough and that's what it looks like LOL.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Limey on Feb 16, 2018, 12:54:39
Most do, usually with a bit of lube and a little love tap everything just kinda pops in.

Can we please stick to engine building?!  :o
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 16, 2018, 13:06:51
Can we please stick to engine building?!  :o

(https://i.imgur.com/mXvKLnK.png)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Feb 16, 2018, 15:21:17
(https://i.imgur.com/mXvKLnK.png)

Always one of my favourites :)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: two-smoker on Feb 16, 2018, 22:16:23
You know there are companies selling Manx look-alike kits with featherbed frames just for those motors,  yeah?

Sent from my LG-LS777 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 17, 2018, 11:27:12
You knee there are companies selling Manx look-alike kits with featherbed frames just for those motors,  yeah?

Sent from my LG-LS777 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

I had no idea. Just googled them and they look pretty sharp. Not really the direction Iím taking this ride though but thanks for the heads up
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 17, 2018, 15:47:30
And at only 20% more than a brand new klr! Or about 2k less than a demo thruxton R at the local dealer. What a steal!


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 18, 2018, 21:05:36
Went out for a skate this afternoon and the ice was like butter.  That's not good.  Nor was attempting anything involving balance and general wellbeing with a hangover a mile wide.

Regardless.

Skates hung, into the garage I trot.  Got the carb all buttoned up with its new Dyno Jet jets and needle etc installed -

(https://i.imgur.com/yYBXzd4.jpg)

I dunno, I really like rebuilding carburetors. 

Also cleaned up the cylinder head as much as I could, and the left the only mark I know how -

(https://i.imgur.com/ARnO9c9.jpg)

and then installed the thing along with a fresh 3 ply gasket.  Got to torquing the head bolts according to Clymers, and found out that they need a final torque of 48 ft lbs which is bloody perfect as my torque wrench starts at 50.  Asked over at advrider (another forum with a dedicated KLR section) and was told that as most torque wrenches can have somewhat questionable accuracy anyway, torquing them to 50 ft lbs instead of 48 will probably be ok.  Probably is the takeaway I took from the conversation, but hey.

I'll torque them to 50 tomorrow and do so without double vision and a head full of broken biscuits.

 

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 19, 2018, 12:01:54
48 ft lbs,
Thatís sounds like a moderate 1.3 second closed mouth grunt to me.
Be sure not to go to far and use an open mouthed grunt. If you find yourself clenching your teeth you might be a few ft lbs over as well.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 19, 2018, 15:22:46
Ha!  Closed mouth grunt it is.

Won't be the only thing I'm using a torque wrench on today.  Hit a fucking pothole/sinkhole and smoked the car's front rim -

(https://i.imgur.com/z3qIhUe.jpg)

Jesus Murphy.  If I was pissed with the state of the shitty roads in this city last week, I'm livid with them now.  Hoping it's just the rim that needs repairing and not the suspension, alignment or brake.  Fuck. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 19, 2018, 15:31:31
Ouch, that sucks. Not easy to straighten alloys either.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 19, 2018, 15:34:42
Wow, must of been one hell of a hole.
It was a puddle wasnít it?
Never hit puddles in Quebec.
Surprised it did that much damage actually, didnít think you could go that fast in the Montreal traffic




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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 19, 2018, 15:44:35
I'm hoping VW will come through - called them this morning and with any luck they can pull it back into shape for around $200.  I'd like to think that time spent calling the city a bunch of wankers would pay off but I doubt it'll do anything other than give me an aneurism.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 19, 2018, 16:11:17
Shit 200 bucks will buy you 4 wheels around here LOL. I run steel winter wheels, Big Fucking Hammer and you can sort them right out because the only province with worse roads than QC is NB. we have 3 of the top 10 worst roads in Canada, QC had 2 LOL.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 19, 2018, 16:25:41
200$
Brand new mag rim
130$
Mounting tire to it 20$
Alignment 65$

Although stealerships have ungodly high hourly rates these days.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 19, 2018, 19:16:40
Shit 200 bucks will buy you 4 wheels around here LOL. I run steel winter wheels, Big Fucking Hammer and you can sort them right out because the only province with worse roads than QC is NB. we have 3 of the top 10 worst roads in Canada, QC had 2 LOL.

Steel's the way forward.  Balls to this whole alloy shite - sure they're fine and snazzy in any other part of North America, the First World, hell anywhere other than Quebec, but here they're a nightmare waiting to get mauled.

Fuck it.

Got the head bolts torqued (very satisfying as it happens), and now working on the cams and timing.  Anyone reading this worked on a KLR before?  Think I've got the process pegged but have a few question marks. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: two-smoker on Feb 19, 2018, 23:19:32
And at only 20% more than a brand new klr! Or about 2k less than a demo thruxton R at the local dealer. What a steal!


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Hey,  featherbed frames are pricey.  😂
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 20, 2018, 20:49:20
After a trip to the local Kawasaki dealership to pick up two tiny o-rings for an oil passage in the cylinder head for $6 ($6??  For two o-rings?  Not for the first time and probably not the last either I'm reminded I'm in the wrong business), I installed the cams, got them timed and put to bed without dropping anything into the crankcase (minor miracle) -

(https://i.imgur.com/yMZloS2.jpg?1)

Coming together mechanics-wise.  Waiting on the frame to come back from powdercoat but with a big bike show here in Montreal this weekend I'm not expecting the phone to ring anytime soon.  Not much else to report, other than my wife made a fantastic roast chicken for dinner.  It's all about the bacon fat under the skin apparently, gets the skin nice and crispy. 

Happy camper.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 20, 2018, 21:41:12
Lookin good there Jimbo, make sure itís not to good looking or youíll feel bad working it out off-road


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 00:32:47
Yanked the snorkel from the airbox - this will dump a load more air into the carb as the stock airbox set up on these KLR's is pretty restrictive.  With the stage 2 dyno jet kit and needle in the carb flinging more gas into the combustion chamber, now that I have more air and a bigger piston, things should go boom - bigger.

(https://i.imgur.com/40DMEHZ.jpg)

Watched a vid on the process, and thankfully avoided the hernia the aussie guy gave himself trying to get the thing out

(https://i.imgur.com/9LlKrZW.jpg)

Air, gas and bigger cylinder/piston - get an iridium spark plug in there to heat things up and I'm off to the races.  Hopefully. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Mr.E on Feb 23, 2018, 11:04:46
Ya gonna be doing any water crossing with it tho? I know for myself I'm a big fan of snorkels on dirty bikes, because there's a 5 year old inside me that can't let a good puddle go unsplashed
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 23, 2018, 11:29:04
Ya gonna be doing any water crossing with it tho? I know for myself I'm a big fan of snorkels on dirty bikes, because there's a 5 year old inside me that can't let a good puddle go unsplashed

Good point E. Jim I'd look at plumbing a bigger diameter snorkel terminating up high enough if you plan to do the water crossing. Hydro-locked motors are not happy motors. Someone on ADV rider or the interwebs must have done the same engine mods and may have a solution already thunk up.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 11:51:53
Funny - I was out the other day for a walk with my mate's 10yr old kid and he did exactly that - charge headlong through Montreal's worst with the abandon that always makes me re-think adult sensibilities.  Puddles put everything into perspective when you approach them with a kid.  Or on a dirt bike.

I did a bit of research before pulling the thing, and asked the KLR guy here in Montreal too what mods to do on the airbox given the kind of riding I plan to do on the bike.  Truth be told I'm not expecting to be fording any rivers any time soon - my offroad abilities are fairly conservative at best.  I used to flog the things around Bali back in the day and nearly came a cropper half way up a volcano, and last year went on a bike trip in Nicaragua which - while not ending in tears - had a few hairy moments.  And all that on dry land.

Incidentally, how high would be considered high water when riding through the wet stuff on a dual sport?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on Feb 23, 2018, 12:12:51


Truth be told I'm not expecting to be fording any rivers any time soon - my offroad abilities are fairly conservative at best. 

I suspect that thought will change once you hit the trails ha Lack of ability hasn't stopped me from being an idiot off-road.

But to be fair, I found a way around the water hole on our Georgia trip when mr.e and irk plowed through it full force.

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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 13:25:02

I suspect that thought will change once you hit the trails ha Lack of ability hasn't stopped me from being an idiot off-road.


Ha!  You're not wrong mate - in my head I was some kind of enduro sensei as I went barreling up 70 degree inclines in the Nicaraguan badlands, but in reality I probably looked more like a duck dancing on a hotplate.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 23, 2018, 13:56:47
Jim, too high = anything above the intake, so a snorkel extends that. if it's as high as the handlebars you can go that deep, at least in theory.  I had a 4 wheeler with a snorkel above the bars and routinely cross water up to and slightly over the bars, just couldn't let off the throttle or the exhaust could fill with water.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 14:06:42
Gotcha.  Up to the handlebars...my speedos would get a decent work out in that kind of high water mark. 

The thing with the snorkel is that it doesn't actually raise the height of the intake, it just seems to focus it.  At least that's how it looks to me.  The snorkel fits inside the airbox, but the mouth of it sits flush with the opening on the top of the airbox.  Removing it doesn't seem to alter the height of the intake, just the capacity.

 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 23, 2018, 14:09:25
Ok that snorkel goes down into the box, is there another that seals against the gasket that goes up under the tank to add height to the intake, that's the important one if there is, if not removing that is a moot point.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 23, 2018, 14:12:42

Incidentally, how high would be considered high water when riding through the wet stuff on a dual sport?

Probably something like this...

 https://m.youtube.com/watch?v=TYB7DYWI4G8 (https://m.youtube.com/watch?v=TYB7DYWI4G8)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 14:15:23
^^ never mind a snorkel, that dude needs an aqualung
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 14:17:08
Ok that snorkel goes down into the box, is there another that seals against the gasket that goes up under the tank to add height to the intake, that's the important one if there is, if not removing that is a moot point.

I don't think so - there's the intake from the carb, but no other snorkel in the airbox itself that I can see. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 23, 2018, 14:23:33
Jimbo, just remember that if you end up dropping her in the drink, you gotta take the plug out before trying to crank it over.

I have the unfortunate experience of sinking a few 2 stroke sleds into a lake with my cousin...
We pulled the plugs, flipped them over and cranked for a few minutes, threw some premix down the intakes and cranked that through. Plugs back in and good to go.
This was after we dragged them back to the shop mind you


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 14:28:06
Do you take the plug(s) out to drain the water from the cylinder?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on Feb 23, 2018, 14:28:08
https://youtu.be/F33nZpWGLvY

https://youtu.be/MCsJqpiVBOI

Dad took his sled out to a friend's Pond some years ago to do some water skipping. Once the friend got on the sled it ended up at the bottom of the drink somehow LOL did much the same pulled plugs, sprayed out water. Had it back together and running again and going across the pond maybe an hour later. That said once we got it back to the shop we had to replace all the light bulbs and the chain case oil as it was full of water.

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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 14:35:10
^^ brilliant - not sure who's having more fun, the guy on the sled or the guy filming him!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 23, 2018, 14:57:30
Ha, I went to the fiche on the KLR and it doesn't show a snorkel and there is a vent tube on the bottom of the air box that if it doesn't have a check valve would become a drinking straw to fill the air box. so I wouldn't cross anything too deep LOL.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Mr.E on Feb 23, 2018, 14:59:04
I can say from my experience of running a uni foam pod on an xr200 that I got significant splash in it just from the back tire.  Maybe not enough to cause issue, but I'm kinda edgy about having mud show up on the filtering agent on a bike built to endure being way out there. And that happened just from a few 6-8" deep splashes and riding in the rain a bit.  On one occasion I'm certain it sucked some water in and ran badly since I found mud inside the filter after a run at an ohv trail. Maybe 12" deep maximum water.  Then on the same bike, I later refitted the stock box and snorkel, and crossed a puddle so deep the front end was bobbing like a river crossing in an old western movie. After that, I found mud in the airbox also.  But, funny thing about design is that the mud was in the low end of the box and able to drain the water out thru the weep hole, while the filter was high and dry up over the step.

So depending on where you wanna ride, the air box delete may work great, but I'd definitely keep an eye on the inside of the filter too, just in case it starts showing dirt
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 23, 2018, 15:51:32
Good call man - like always I'll be listening to advice I'm getting from you guys who have been at this a lot longer than me. 

Just to clarify - I won't be removing the airbox itself, just the snorkel that snakes inside it.  With the snorkel thing removed, the air intake is still at the same height it was before, and as far as I can tell all that will happen is that more air will be drawn through the box and into the carb.  The mouth of the intake itself is protected by the side cover and lies on a horizontal axis - I'm told removing the snorkel will result in a slight whistling noise, but hopefully that'll be more than covered up by my hollering as I tear strips off the Quebec countryside.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 23, 2018, 15:55:57
That's what I thought and was going to ask. should be ok, may get a little more dust and stuff in but the plate and filter should catch it.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: doc_rot on Feb 23, 2018, 16:33:03
since were posting crazy vids of vehicles that shouldnt be on water on water..... go to 2:20 for the madness to start 
https://www.youtube.com/watch?v=lDi9uFcD7XI
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 23, 2018, 17:07:16
since were posting crazy vids of vehicles that shouldnt be on water on water..... go to 2:20 for the madness to start 
https://www.youtube.com/watch?v=lDi9uFcD7XI

Thatís cheating
But still insane what a few mods will do to a bike.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 24, 2018, 11:29:10
^^ Damn. He beat me to it. I was planning the same stunt at the local leisure pool. My fat mate was going to take a header off the high board and Iíd surf his bow wave on the KLR.

Back to the drawing board.


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Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 24, 2018, 19:26:21
[IMG]

Christ doing cartwheels. 5 1/2 hours.  Thatís how long it took to clean up, sand and polish this rear fender.  I could have watched Apocalypse Now Redux twice in the same time. Almost.

Iíve drunk a lot of beer. My arms are fucking killing me and Iíve got through about 477 sheets of sandpaper.

Perfect?  No.  Happy?  Happy enough.  Addled?  Somewhat.  Restoring plastic is a thankless task and one I would recommend to absolutely no-one.  Ever.

Thank god for ales.


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Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 24, 2018, 19:27:44
This is how it looks -

(http://i.imgur.com/dxN0fAV.jpg) (http://imgur.com/dxN0fAV)

So.  Green. 🤪

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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 24, 2018, 19:34:35
Mmmmh, granville island pale ale.

Fender looks good too jimbo


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Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 24, 2018, 20:26:10
Thanks mate.  Missed dinner so now have a Dr Oetkers in the oven.  So that's a win.

Sanded off my thumbprint, again - can't get into my iPhone, again.  Life of crime beckons.  Might half inch a dozen bikes at the moto show tomorrow, fingerprint the shit out of every booth and then get back to the garage and restore a plastic headlight cowl.  Totally in the clear.
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 27, 2018, 20:32:57
Small win today, but a win nonetheless.  I've tried every short cut known to man to try and speed up the restoration process for these plastics, but none have worked.  No kidding they didn't work.  If they worked, someone would have posted a video on Youtube by now titled something along the lines of "Shortcut to Restoring Plastics!!!" and I'd've been all over it like white on rice.  There is no shortcut.  There is no Youtube video.  The process is truly an almighty and monumental ball ache.

However I did find a better process - kick it down a gear and start at 220 grit rather than 320.  Sure you get deeper scratches in the plastic and then have to get those scratches out with the 320 and so on and so on, but the initial sun oxidization only takes an hour to get out of a 12"x3" patch rather than three.

I know, the irony is not lost on me for one minute that I am restoring the plastics on a dual sport.  A dual sport than will be treated with all the respect any dual sport deserves.  But still.  That's how I'm wired.  If it can be done, I'll give 'er.

Here's a before.  It may be hard to see any actual progress but believe me it's there.  The bit I circled in blue is the top portion of the side panel until this morning covered by a large KLR sticker, where you can see the original plastic colour.  I've only worked that top section so far -

(https://i.imgur.com/vYWtjut.jpg?1)

but you can see how the oxidation has been removed now and the original splendour of that pea green is back in full - if not shiny - force...

(https://i.imgur.com/bl3BzGr.jpg)

Damn.  There's a lot more interesting and impressive stuff going on on DTT right now, so I'm leaving you there. 

Here beer here.

Edit -  Shit.  Maybe there is a shortcut. If there is I hope truly and very sincerely that I donít find out as soon as Iíve finally finished this.
Title: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 27, 2018, 20:52:18
Are you doing all that sanding by hand Jimbo?

Cheers
(https://uploads.tapatalk-cdn.com/20180228/946b162ee08f6818c19c5c6d6ac45877.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 27, 2018, 21:00:51
Yes mate.  Not sure there's an alternative - thought about using an orbital sander but they'll just dump a load of spiral scratches in the plastic that'll suck to get out. 

Is there an alternative?   Is there?  To say I'm all ears if there is would be the understatement of the millennium.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 27, 2018, 21:04:41
Mmmmm, love me a nice blonde.

Cheers fella

(https://i.imgur.com/EjMPIPa.jpg?1)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 27, 2018, 21:09:43
Yes mate.  Not sure there's an alternative - thought about using an orbital sander but they'll just dump a load of spiral scratches in the plastic that'll suck to get out. 

Is there an alternative?   Is there?  To say I'm all ears if there is would be the understatement of the millennium.

Dual action sander?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 27, 2018, 21:11:02
 https://m.canadiantire.ca/products/productDetail/0589325P/false/false/false?selectedSku=0589325 (https://m.canadiantire.ca/products/productDetail/0589325P/false/false/false?selectedSku=0589325)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 27, 2018, 21:12:29
Dual action sander?

Iím choking on my beer and googling it immediately...


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 27, 2018, 21:16:13
Mate would that thing work on plastic? You ever tried it?


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 27, 2018, 21:18:43
Never tried restoring plastic, but if i remember correctly they orbit spin so you donít get swirling.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: doc_rot on Feb 28, 2018, 04:25:30
A DA sander if used properly wont leave swirl marks, the big thing is to not stop the pad spinning. if you get swirl marks you can work up in the grits they pretty much disappear. you can get orbital sanding disks in just about any grit. that's how body shops do a ton of sanding.  FWIW I have noticed that some plastics, like ABS, if you sand to a fine grit (800) and wipe the surface with some acetone the plastic melts slightly and the surface becomes glossy again.

https://www.youtube.com/watch?v=rZZyypf-Qqk
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 28, 2018, 10:13:10
Thanks for the input guys - watched that vid hypnotized this morning.  Too bad he didn't show the wood in its final, polished splendour...

Thing is, that sander looks like it'll work great on flat or slightly curved panels, but most of the plastics on my bike are irregular, concave or too small to get that thing in there.  I'm sure in the right hands it could work on plastics, but in mine I can see gouges and all manner of twattery.

I'll give the acetone suggestion a run for its money.  I had considered trying that.  Kinda like the somewhat matte finish I'm getting at the moment (it goes well with the brushed steel tank) but it's worth a try. 
Title: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Feb 28, 2018, 11:19:10
Have you considered a few passes over it with the blowtorch?
https://m.youtube.com/watch?v=RVLfR--ES1k
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 28, 2018, 13:20:38
Thought about it mate but not sure I'm going to be happy with the results.  I know me - I don't exactly like making life difficult for myself, but that's often where I find myself regardless.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Feb 28, 2018, 13:51:10
The acetone wipe is like a chemical blow torch.  It chemically melts the surface then it re-hardens when it evaporates.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Feb 28, 2018, 13:53:42
^^ I'm going to give the acetone a try
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Mar 01, 2018, 11:26:30
^^ I'm going to give the acetone a try

Any excuse to use hazardous chemicals amirite?  ;D
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 01, 2018, 11:38:54
Any excuse to use hazardous chemicals amirite?  ;D

Yessir - the psychedelic maelstrom that kaleidoscopes wildly in my field of vision on a semi-permanent basis while mucking about in my garage ain't gonna feed itself ya know...
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 01, 2018, 11:50:40
Speaking of which, this band came into my world this morning -

https://www.youtube.com/watch?v=RnsZUbWAu2I

Oh Sees.  Damn...
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 01, 2018, 12:21:21
And the spidervibes continue with The Lemon Twigs...

https://www.youtube.com/watch?v=xQ4nqnVOfMo

Thursday gotten into gear with uncharacteristic flair for this time of week.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 01, 2018, 18:43:49
Frame, swingarm etc back from powdercoat today, no pics but man they looks sharp.  Could not be happier. 

Now the fun begins...
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Mar 01, 2018, 21:56:45
Whereíd you get it done Jimbo?
Care to disclose what they charged ya?


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 02, 2018, 10:02:23
Whereíd you get it done Jimbo?
Care to disclose what they charged ya?


Sent from my iPhone using Tapatalk

I know a guy who knows a guy and that's about all she wrote.  But pm mate if you ever need any work done and I'll point you in the right direction no worries.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 02, 2018, 18:49:30
Pretty close to the original frame colour, but a little more metallic -

(https://i.imgur.com/J7YX58V.jpg)

Cold and damp as a witch's tit in the garage so didn't get much further than oggling my new frame.  Leather shot bag and nylon shaping hammer arrived today from Princess Auto so pretty soon I can fabricate stuff.  So as to be able to say I've fabricated stuff as much as anything else. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 05, 2018, 22:04:16
Got the beginnings of a KLR-shaped thing in my garage again.  Heaved the engine off the work table and onto the jack -

(https://i.imgur.com/hZv231sh.jpg)

then onto the floor -

(https://i.imgur.com/LqRpd8U.jpg?1)

then wriggled the freshly powdercoated frame onto the engine -

(https://i.imgur.com/TOtsbLU.jpg?1)

and finally hauled the whole lot upright again once I'd finger tightened all the bolts -

(https://i.imgur.com/ihy3WTL.jpg)

Took a fair few moves to make it happen but managed not to knick the frame and hopefully everything's back where it should be.  I also removed the valve cover to gain some precious few inches of clearance, but whipped up a temporary cover from shop towels and duct tape.  Ghetto moves FTW. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 06, 2018, 00:34:13
Damn, just noticed the dark red towel under the silver frame looks righteous.

Doubt the wife'll agree, she loved that towel.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 07, 2018, 11:30:50
After powdercoating I had new bearings installed in the swingarm, and also noticed that the suspension linkage had taken one for the team.  The outside edge had taken a clatter at some point which had dislocated the seal and allowed crap to get inside.  Before reinstalling the seal I wanted to make sure this didn't happen again and so cleaned up the whole linkage assembly -

(https://i.imgur.com/pFnR0nQ.jpg)

Now the bearings, spacers and seals are all doing the job they're supposed to.  Now I know how to do it, the next time I re-install the rear suspension and linkage it'll probably take about 20 mins.  Last night however it took about three hours.  Still, now I know.

(https://i.imgur.com/2zcjo9i.jpg)

Also cleaned up the bearings and races on the steering stem and installed the triple tree.  Some powdercoat had got into the stem hole on the upper clamp and man it took some budging.  Good thing too - I know for sure the powdercoat on the frame is strong and great quality.

There's a few washers missing from the steering stem assembly which I now have on order, and need to pick up a 30mm (I think) socket to tighten up the top nut.  Any excuse to duck out of work for a bit to go to Canadian Tire...
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 08, 2018, 21:17:32
Rear wheel all sorted - bearings, spacers, sprocket, hub...the lot.  This bike had never seen asphalt in all its 17 years before I bought it - it's entire life had been spent on the trail.  And most of that trail was all over the rear wheel. 

Now it's all greased up with happy bearings and kinda clean spokes -

(https://i.imgur.com/UXN7IQp.jpg)

Got it installed after realizing that powdercoated surfaces can really throw tolerances out of whack.  The caliper bracket wouldn't fit on the swingarm and the axle wouldn't fit either.  Discovered - and not for the first time - that the powdercoat job on this frame is excellent

(https://i.imgur.com/vlrs939.jpg)

Onwards and upwards
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 08, 2018, 23:58:12
Looking good Jim. And yes powder can add a lot of thickness to stuff
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 10, 2018, 20:25:04
Front hub bearings and spacers buttoned up today, and the rim, spokes, brake rotor and hub given a thorough clean.  I'd already installed new fork seals last year when I had to get the bike through the SAAQ ball ache (Quebec vehicle inspection) so the only other thing they needed was a good clean and new boots.  The original ones (gaiters) were very purple and therefore going cheap - anyone need 'em let me know.

Had to remove the swingarm as I realized the hard way that I'd forgotten to install the rubber chain guard.  Bollocks.  Job done, chains on and things are starting to look decidedly bike-like...

(https://i.imgur.com/BgkSawi.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Mar 10, 2018, 21:07:32
I hope you'll still want to get this thing dirty when it's done.  ;)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 10, 2018, 21:19:51
D. I. R. T.           Y?    Coz I gotta   


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 11, 2018, 13:08:12
Nice work Jim.  Looking good.  Now I Incoukd just selk the cx something like this will be in the garage.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 12, 2018, 12:18:43
Cheers Mike - good luck shifting the CX and hopefully you'll land a thumper in time for a jolly around Gaspe this summer...

Got the rear subframe bolted on yesterday but only after working out some powdercoat from inside some of the threads.  Not a huge deal as I'll be drilling out the frame at some point down the road and installing one through bolt as opposed to the the two stock bolts for greater strength.  However also realized that the airbox needs to be installed into the subframe before fitting it, so I'll be pulling the thing off again this arvo.  Carb's installed, and I'm going to have to source some frame brackets as at some point in this bike's chequered past a whole battery had emptied itself down the left side of the frame.  Easier said than done.  Model-specific parts for the C model are very hard to find here in N America as it was only sold here for a year or two, and only then in Canada.

Need to get me some CAD skills, pronto.

(https://i.imgur.com/bfTwAIu.jpg)

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on Mar 12, 2018, 12:21:57
If you sketch up what you need on a piece of paper with dimensions, I can draw you something up in 2d cad easy enough if you need
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 12, 2018, 13:15:17
Damn that's a really nice offer, thanks man I appreciate that a lot.  I'll call my local Kawa dealer today and see if they can get me the pieces I need and if so for how much, but if it's a no then I'll let you know for sure.  Thanks fella, good man.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 12, 2018, 13:33:02
This is what battery acid can do to a frame and its brackets -

(https://i.imgur.com/q6WDshS.jpg?1)

The frame's all good now but that bracket has really taken one for the team.  It's a mounting bracket for the airbox and now looks like it's been buried underground for about 450 years.  I'll see what gives when I call Kawa, hopefully they have one and won't charge me the earth for it.  Stranger things have happened.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 12, 2018, 13:47:14
If that's on a rubber damper then it might not be "C" specific as it looks the same and the one on the 00 KLR650 parts fiche on bikebandit. If that is true your dealer should be able to get one for you easy.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 12, 2018, 14:11:12
Just got off the phone with Kawa and they can get me the part - it was a little unclear as to whether or not it's C specific.  As the rear subframe on the C is different to the A then it wouldn't surprise me if the part was specific but no matter, I'll get my mitts on the thing in a few days.

Guess it's a double edged sword, the rarity of this bike.  Makes finding C-specific parts quite difficult, but I do have a ride that's pretty uncommon.  Gotta love that.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 12, 2018, 17:11:19
These just showed up, should be a decent fit with the whole green and steel vibe of the bike

(https://i.imgur.com/bXT4pNG.jpg?1)

Got some Spray Max 2K clear on order then it's time to clear the tank.  Once I figure out the decal I'll be sticking on the thing Ill be good to go, just gotta make some measurements etc.  The 2K stuff worked out pretty well on the CB750 so using it again was a no-brainer.  I'll try the gloss this time and see how the brushed steel works with that.  One way to find out.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Mar 12, 2018, 20:49:18
Man jimbo, you are really making me miss my little TC185 with this thread.
Only bike i ever regret parting with.
The hi/lo range was the tits for bombing through the woods on low and then flip into the hi five for down the back roads.

(https://uploads.tapatalk-cdn.com/20180312/6edcb4f0c95273d55ccef41e9efbe867.jpg)

That battery acid is nuts.
We were adding acid to the water in one of our barns, and any steal fittings down stream of the acidifier just corroded to shit within the first year, and that was only at a PH of 4.5.

Glad to see youíll soon have a proper vehicle for navigating montrealís springtime streets.


Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Mar 12, 2018, 21:21:53
Hey Jim, have you tried sourcing your bracket on a KLR forum?

Very nice work so far.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 12, 2018, 21:31:20
Thanks guys, appreciate the good vibes as always...and that Suzuki looks like it's got some gnarly stories to tell...

The KLR forum was my next stop if Kawasaki came up short, but turns out they could get me what I needed and it wasn't crazy expensive either.  Good call though.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 13, 2018, 20:16:49
I guess like a lot of you guys do I bag and label everything when I take the bike apart, and take a ton of photos.  This morning's breakfast is a bit of a blur let alone where a wire I unplugged 4 months ago is supposed to go.  So I bag everything, labelled in big black sharpie letters, ready for the rebuild.  To be sure.

Except I don't. 

I should, and do with almost everything, but somehow for some reason some parts just slip through the net.

And so I spent 2 hours trying to figure out where the fuck this one - unlabelled - rubber bung and bolt was supposed to go.  2 hours. 

Note to self - label everything.  Eh-vree-thing.

After that snafu things went swimmingly.  Got the airbox on, hooked up the carb, bolted the radiator back on and made a good fist of the wiring harness.  It was in a right old state and needed a fair bit of re-wrapping and cleaning up but looks less like a pile of filthy fear under my workbench now and more like the central nervous system of my motorcycle that it is.

(https://i.imgur.com/f0uFdRg.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 14, 2018, 18:01:50
Weather's gone totally tits up, woke up to a foot of snow and car got stuck in a drift.  This'll be the last year I fuck around with front wheel drive, leasing something red and with AWD as soon as.  Picked up a can of this stuff -

(https://i.imgur.com/XQqEIDd.jpg)

- it worked great on the Honda so I'm gonna hit the tank with gloss this time and see what gives.  The "professional use only" sticker on the lid - pfffffft.  Hazardous chemicals and me have a history now.  Hoping to clear the tank in the next few days and then finally get to see how it looks with those restored green fairings.

RIP Stephen Hawking.  Woke up to that sad news this morning, that dude had game.
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 18, 2018, 01:39:28
Tore my thumbnail off this afternoon cleaning up the rear brake caliper.  Hurt then, pounding now.  I suppose that means I'm about 2mm narrower. A customization I can see no benefit in whatsoever.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Mar 18, 2018, 15:26:46
Tore my thumbnail off this afternoon cleaning up the rear brake caliper.  Hurt then, pounding now.  I suppose that means I'm about 2mm narrower. A customization I can see no benefit in whatsoever.

Cringe!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Brodie on Mar 20, 2018, 04:33:10
I feel your pain. Hope the injury doesn't slow you down too much.

Sent from my K6 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 20, 2018, 09:50:32
I feel your pain. Hope the injury doesn't slow you down too much.

Sent from my K6 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Compared to the injury you had mate mine wasn't even a graze.  I burnt my index, middle and ring fingers on the stove last night - it's a bad week to be a digit on my right hand.  Hope you're all good - I've been keeping an eye on your Ugly Punx thread but haven't seen any updates for a while.  How did you get on with that saddle?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Brodie on Mar 20, 2018, 10:24:42
Still waiting to be upholstered. My missus is off work with a broken foot so I have no motorcycle funds at the moment.

Sent from my K6 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 20, 2018, 10:31:32
Still waiting to be upholstered. My missus is off work with a broken foot so I have no motorcycle funds at the moment.

Sent from my K6 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)
Sorry to hear that mate, hope sheís on the mend in no time and youíre back in the saddle


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 20, 2018, 10:37:35
torn nails suck. I chopped the end of my thumb off about 2 months ago, it's healed but still super sensitive to heat and cold etc.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 21, 2018, 11:36:34
Jim, you need to drink more beer, the can you bought should fit your bike from the looks of these 2 photos. your bike on top. Bike from the site you got your can from. the frame and routing look identical to me, I could be wrong but check it out.

(http://www.dotheton.com/gallery/1732-210318093532.png)


Maybe they sent the wrong mid-pipe by mistake?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 21, 2018, 12:03:15
I need more beer.  Never have truer words been spoken my friend =)

The rear subframe is different on my C (that's an A model in the lower photo) but without looking at them both next to each other I'm not sure what the differences are exactly.  The rear brake reservoir bracket is one difference, and maybe some mounting brackets on the frame itself.  From what I can tell the mid pipe I have is too short to route around the frame correctly so it's possible I have the wrong one. 

It's hard getting to the bottom of it as Lexx is an in-house brand of Rocky Mountain ATV, and there's no Lexx representative per se that I can speak to to find out what the problem may be.  I'll take some measurements and make some calls.  Really hoping I can make it work - it was about half the price of other brands like FMF, Two Brothers etc but comes very well reviewed.

But regardless of all that, you're right.  I need more beer.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 21, 2018, 13:02:58
Exhaust snafus aside for a moment.  I've been looking forward to officiating on this particular marriage for some time - the tank and the restored fairings.  Got the tank cleared yesterday with SprayMax 2K "Glamour Clear" - it's a high gloss clear coat compared to the satin clear I used on the CB. Gotta say I love this stuff.  There's a button on the bottom of the can that you push which activates some kind of hardener in the aerosol - this stuff sprays on smooth and sets hard.  It held up great against gas spills on the CB so all being well it'll do the same here too.  It's about as good a clear coat as you can buy in a aerosol as far as I can tell - can't speak highly enough of the stuff.  You only get about 24 hours from pushing that bottom button to it going off in the can, but I used the whole lot on the tank anyway.  But it's brutal on the airways - you gotta dust off your Breaking Bad halloween costume and go full hazmat with this stuff.

Figured I'd try the gloss this time on the tank as the plastic fairings came out with more of a matte finish after all the sanding, which I like.  Very happy with the contrast, and starting to see things come together now -

(https://i.imgur.com/bS1LGsP.jpg)

Aesthetics-wise a bunch more to do - seat still needs re-upholstering and the side panels will be getting a steel panel detail on them sooner or later too.  Shaping up.     
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 21, 2018, 13:09:53
That looks great! I like it and +1 on the spraymax 2K it is as good as you can get, it's the same as pro 2 stage clear you'd use in a body shop and yes you need full respirator and cover all of your skin too as it can get into you from skin contact and eyeballs.  I am betting you got the wrong mid pipe as the places your subframe differs are not where the exhaust routes. your header is identical to the A model and I bet the oem exhaust is the same on both models.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Mar 21, 2018, 13:18:57
(https://i.imgur.com/bS1LGsP.jpg)

Now that is just delicious.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 21, 2018, 13:21:10
Check this pic, I added the A exhaust and it's identical to the C in your pic. I am now convinced if the Lexx won't fit it has the wrong mid pipe. They make a lot of kits for that pipe and getting the mid pipe wrong could easily happen, especially made in China.

(http://www.dotheton.com/gallery/1732-210318111907.png)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 21, 2018, 13:45:16
Thanks gents, pretty happy with how it came together.  I'm a sucker for green at the best of times, but the matte pea green against the glossy brushed steel looks pretty sharp.  Looking forward to making the panels for the fairings and seeing how they look.

Man I really appreciate the help on this exhaust situation, thanks mate!  I'm going to have another look at the set up this eve and see what gives.  You could well be right - maybe they sent me the mid pipe for the newer E model by mistake.  I'll call Rocky Mountain and see if they can help - they were great on the phone the other day when I was arranging the return.  If I can get another mid pipe sent over then hopefully I can get this hooked up and not have to hunt for another can.  Now that the cylinder has been bored out to 685, airbox modded and carb re-jetted and needled I really need a less restrictive and - lets face it - better looking muffler than stock.  Fingers crossed the exhaust gods look on me fondly.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 21, 2018, 14:09:45
Still mucking about with the shape and cut outs.  Maybe something like this -

(https://i.imgur.com/WqkDHog.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 21, 2018, 22:34:50
Ok, well I'm not calling myself a massive bell end yet but it's dangerously close.  Think I've got to the bottom of the mid pipe drama - Mike you're absolutely right.  Although the sub frame is different, the exhaust header and silencer on both the A and C model is - as far as I can tell - the same.  The difference is the frame mounting points, but I can work around that.  Can't be 100%, but I think the problem I had yesterday was the header flange was on the wrong way round, throwing everything off.  That or the internal flange in the mid pipe was in the wrong end.  That would make me feel a little better about things as it came that way.

Think all may be well.   ::)

*exits stage left, rather sheepishly*
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 22, 2018, 08:41:58
We've all been there and that's what DTT is for, post it up and let the masses help LOL. Glad you will get it sorted. As for the can mounts they can be moved forward and back on the can right? You may need to use a small bit of plate to adapt it also.  Cheers
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 22, 2018, 09:46:33
Yeah man, the can itself has moveable straps so I should be able to find a sweet spot.  Gonna pick up some high temp RTV gasket sealant today and hopefully get this thing hooked up.  To say it'll be a relief will be a massive understatement.

Good on ya fella - flat bread pizza and beers at Les Trois Brasseurs whenever you're in town again
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: SONIC. on Mar 22, 2018, 10:08:44
I love that bare metal with the gloss clear. looks Fantastic man
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 22, 2018, 10:19:03
I love that bare metal with the gloss clear. looks Fantastic man

Figured I'd take a punt with the gloss this time and glad I did, shows up the brushed effect in the tank really nicely.  Thanks man  8)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 22, 2018, 10:25:03
Yep the tank is great, hopefully you got all the possible moisture out so it lasts without rusting on you. Worst case is you have to clean it up every few years and re-clear but hopefully not.  Don't use RTV on the pipe. you'll need muffler cement to take the heat. They sell it at crappy tire in the exhaust section.
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 22, 2018, 10:31:07
Yep the tank is great, hopefully you got all the possible moisture out so it lasts without rusting on you. Worst case is you have to clean it up every few years and re-clear but hopefully not.  Don't use RTV on the pipe. you'll need muffler cement to take the heat. They sell it at crappy tire in the exhaust section.

Gotcha, thanks mate - Iíll make sure I get the right stuff. Got the header and heat shield sandblasted yesterday so Iíll be picking up some VHT exhaust paint while Iím at it.

Itís no Harbour Freight, but I love me some Canadian Tire.

Time will tell whether I get rust underneath the clear - I had the shop heater pointed right at the tank for a good 24hrs prior to clearing it in the hope I could drive out as much moisture as possible. Weíll see.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 24, 2018, 22:15:03
Slowly but surely getting the exhaust mounted but it's no shoe-in.  Nevermind that - bought some high temp exhaust cement to seal the muffler to the mid pipe but it dries really brittle - any movement and the seal cracks.  Canadian Tire does sell some high temp RTV silicon that can be used on exhausts - will that have more flex?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Mar 24, 2018, 22:28:16
How big is your gap? You're probably supposed to be running a gasket...

https://www.ebay.com/itm/Kawasaki-KLR-650-A-87-CC-EXHAUST-CONNECTION-GASKET/400605359252?hash=item5d45f0ac94:g:bTQAAOxypNtSgJ2J&vxp=mtr

https://www.ebay.com/itm/Exhaust-Pipe-Gasket-Fits-KAWASAKI-KLR650-KL650-1987-2010/282064551139?epid=20003209022&hash=item41ac5b7ce3:g:mwYAAOSwuhhXWvk2&vxp=mtr

(https://i.ebayimg.com/images/g/mwYAAOSwuhhXWvk2/s-l1600.jpg)

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 25, 2018, 11:36:19
I'm using the stock header but with an aftermarket mid pipe and muffler from Lexx.  The tolerances are pretty tight - using the stock header clamp I can get the mid pipe on the header pretty snug, but the mid pipe into the muffler is a bit wobbly.  Maybe less than a mm, but enough for it to break the cement seal.  No way I'm getting a gasket in there though.  Think the high temp silicone would work?  Need something with a bit more flex, or figure out some other way to tighten up the muffler/midpipe seal.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 25, 2018, 11:51:48
Blue skies and melting snow, spring is most certainly here and things are starting to look two-wheeled again, even seen a few brave souls on bikes tooling around the city already.  Jonesing to join them - if the weather holds I'll try and fire up the CB750 next week and get mobile.  In the meantime making progress in the garage, got the header and heat shield sandblasted and painted -

(https://i.imgur.com/phqkpv8.jpg)

and after much finagling got the Lexx exhaust installed.  Very tight tolerances with this exhaust on the C model, but doable.  Had to modify the sleeve inside the mid pipe - it wasn't biting down enough on the stock header for a tight fit so filed the gap down to allow it to close further, jammed a socket in there and had at it -

(https://i.imgur.com/gd6TVoJ.jpg)

Once I got the muffler on I tried MacGuyvering the exhaust springs into position and narrowly avoided losing an eye when the spring snapped and took a small chunk out of the wall behind me.  Gonna need some longer exhaust springs if I stand any chance of getting them on.  Also had to cut a chunk out of the mudflap to create more space for the mid pipe, things really are tight in there.

Like how this thing looks, looking forward to hearing how it sounds.  Has a removable spark arrestor so if I want to challenge the finely wrought relationships I've developed with my neighbours I can pull that thing out and test the limits of friendship.  Apparently, things can get loud.

 (https://i.imgur.com/5srzdLX.jpg)

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Mar 25, 2018, 11:57:49
Hot damn jimbo, that thing is looking mean!!

Got a brave soul thatís been riding past my house every day for since the 10th on his Adv bike, (except maybe during the snow storm) heís a real keener.

I might have missed it, but what colour are you putting on the seat?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 25, 2018, 12:07:14
Hats off to those guys - mate of mine is picking up his ride from storage out in the sticks and riding it back to MTL today, lovely day for it but I hope he packed gloves. 

The seat will probably stay as is for the time being, it's not in bad shape and I like the very dark grey, non-slip cover someone stapled on it once upon a time.  I'll probably keep it dark grey but maybe with a kawa green detail.  Need to convince the missus/boss that that is a vital thing to do.  Not sure she's convinced.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Mar 25, 2018, 12:27:52
If you're talking just 1mm, then make yourself a shim with sheet metal, a piece of thin pipe that's split, or even a beer can.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 25, 2018, 12:35:03
If you're talking just 1mm, then make yourself a shim with sheet metal, a piece of thin pipe that's split, or even a beer can.

Beer can - perfect.  That'll do it.  Have a full beer can, will empty it in the appropriate manner and get that sucker in there.  What's the verdict on the high temp silicone by the way? 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Mar 25, 2018, 12:42:35
Beer can - perfect.  That'll do it.  Have a full beer can, will empty it in the appropriate manner and get that sucker in there.  What's the verdict on the high temp silicone by the way?

It works okay, make sure you put it on in a way that doesnít make a mess everywhere inside and out of the pipe.
Use it often on spring mounted 2 stroke expansion chambers, it works all right.
The best for sure is to shim it with something solid if the gap is too large.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Mar 25, 2018, 13:52:09
Never tried high temp silicone, but if it handles the temps, I don't see why not. BMW calls for a cement on airheads where the headers screw onto the heads.  It's the only time I've ever used anything like that..
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 26, 2018, 11:03:42
Getting closer now, still got a bunch of things on the to-do list but for the last 24 hours I've had this Far Side cartoon in my head -

(https://i.imgur.com/2A62ruz.jpg)

I Am The Optimistic Arachnid.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: JSJamboree on Mar 26, 2018, 11:31:48
New to this thread, but im concerned that this KLR doesn't look like a giant turd.  Its going to confuse people
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 28, 2018, 13:54:54
Oh, turd potential is still there mate, there's many a slip twixt dress and drawers
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 29, 2018, 19:50:19
Got the fluids in (coolant and oil) - after much deliberation with those that know about these kinds of things I went with Rotella T4.  Coolant pissed all over the garage floor but was half expecting that - the drainage hose from the reservoir is ludicrously close to the exhaust header and is known to melt.  I tried to jerry rig the hose onto the melted spout but clearly to no avail.  A job for the to-do list.

With oil in the engine I installed the battery (lights indicators horn - all the usual suspects seem to work ok so my wiring so far seems up to snuff), removed the spark plug and cranked the engine for about 15 seconds - plan being to move oil up to the valves and overhead cams and, well, all through the engine.

Think 15 seconds is long enough to get oil to everywhere it needs to be?  Just want to make sure everything is properly lubricated before firing up the oil girl for the first time with her spiffy new piston and rings.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Mar 29, 2018, 20:34:42
It might be. Does it have tappet covers to see if oil is in the head? If not turn it over a few mote times to be sure
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 29, 2018, 21:43:55
It doesn't, but I could pull the valve cover off and have a look.  Probably best to be sure
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: stroker crazy on Mar 30, 2018, 00:21:27
Probably best to be sure

What sort of attitude is that?

Crazy
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Brodie on Mar 30, 2018, 03:09:58
The optimistic spider attitude!

Sent from my K6 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 30, 2018, 21:29:18
What sort of attitude is that?

Crazy

Yikes.  Not the right one? 

You think that's questionable you should've seen how I got the bike off my seized jack this afternoon, whoa nelly. 

It's all good my man, really just wanted to know how long it takes to circulate oil through the top end of an engine simply by cranking it.  For all I knew could've taken seconds, could've taken hours.  Now I know.

Got a bunch of stuff dismantled and then got the valve cover off, got some more oil in there (and carefully down the spark plug hole) - when I fire this thing up Iíll know things are oiled up and ready to rumble.
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Mar 31, 2018, 21:54:13
Enough faffing - got some gas in the tank, hit the start button and damn if it didn't fire right up the first time - El Verdito is alive.  Dialled in the idle screw, adjusted the throttle cables, the new pipe sounds excellent and the thing is thumping away with no small gusto.  Terrific - first time I've rebuilt an engine to this degree so really I could not be happier.  Of course I'm yet to go for a ride so managing my expectations.

Then the fucking petcock starts leaking again so, well, balls.

One of the captive nuts inside the tank that the petcock bolts into is stripped.  No bueno.  Made a few adjustments, added some plastic washers and now have the tank filled with gas sitting over an oil pan to see if the fix is gonna hold up. 

(https://i.imgur.com/F0k5Whd.jpg)

Hope this Easter bunny won't lay shit.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 01, 2018, 12:11:05
Hope the fix holds up. Happy easter. Great to hear the first fire went well.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 01, 2018, 19:55:22
Happy Easter one and all.  The tank fix seems to have worked, at least for now.  Might benefit from some gas-resistant gasket sealant but for now it's holding.  The coolant reservoir however, not so much.  Managed to get hold of another tank from another model KLR, and with a bit of modification got the thing installed.  The problem with the original one was the lower outlet had melted due to its daft proximity to the exhaust header.  Decided to make a heat shield to prevent the same thing from invariably happening again -

(https://i.imgur.com/Q7VqYsI.jpg)

Think that should do it -

(https://i.imgur.com/0r5Z8zw.jpg)

Slung the saddle on the bike and went to take it down the back alley, but as soon as I put it in gear it stalls.  Think it's got something to do with a clutch safety switch - either in the clutch lever assembly itself or in the wiring harness somewhere.  In the hope that someone may be familiar with this problem, here's what I disassembled from the clutch lever housing -

(https://i.imgur.com/T4YYjz0.jpg)

I did take the lever off to sand it, in doing so there's every possibility that something fell out that is causing the problem, but the above photo shows what I took out.  A plate with copper rails, a small plastic post with a copper top and the housing.  Should there also be a spring or something?  Beats me.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Apr 01, 2018, 21:28:44
Jim, could you just run a tap through the petcock bolt threads on the original tank and put the next size bolt/screw in it?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Apr 02, 2018, 06:59:45
http://advrider.com/index.php?threads/klr-clutch-neutral-bypassing.611580/

A thread with links to more threads about bypassing the clutch safety switch.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 02, 2018, 10:15:55
Jim, could you just run a tap through the petcock bolt threads on the original tank and put the next size bolt/screw in it?

That's the plan Nick if the tank starts leaking again.  So far it's holding up but I'm keeping an eye on it.  Right now there are 6mm bolts in there - ideally I'd tap to 7mm but apparently 7mm bolts don't exist in Canada.  Not readily anyway, so not sure if there's a 7mm tap.  If not I'll have to go standard and get the next size up.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 02, 2018, 10:18:08
http://advrider.com/index.php?threads/klr-clutch-neutral-bypassing.611580/

A thread with links to more threads about bypassing the clutch safety switch.

Thanks fella, I'm a member of that forum too so hopefully I can get to the bottom of it.  There are a bunch of safety kill switches on the KLR - one for the kickstand and one for the clutch - so I'll have to revisit the wiring and see what gives. 

I say that like I know what I'm doing, which is funny.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Apr 02, 2018, 10:29:20
Just use Heli-coil or Time-Sert and keep the thread stock.
Title: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Apr 02, 2018, 10:31:48
That's the plan Nick if the tank starts leaking again.  So far it's holding up but I'm keeping an eye on it.  Right now there are 6mm bolts in there - ideally I'd tap to 7mm but apparently 7mm bolts don't exist in Canada.  Not readily anyway, so not sure if there's a 7mm tap.  If not I'll have to go standard and get the next size up.

Why bother staying with metric though imperial sizes are more readily available and you can find one thatís just a tiny bit larger than the 6 mm
1/4Ē
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 02, 2018, 10:36:33
So looking at your wiring diagram your neutral switch, sidestand switch and clutch switch are all linked so anyone of those not working or connected right will give you grief.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 02, 2018, 11:11:22
So looking at your wiring diagram your neutral switch, sidestand switch and clutch switch are all linked so anyone of those not working or connected right will give you grief.

Pretty sure you just nailed it.  There was some kind of switch set-up above the kick stand which I removed, thinking doing so would then bypass the kick stand safety switch.  Not thinking that removing it entirely would break a circuit.  I'll reinstall the switch and plug the thing back in, see what gives.  Thanks for the insight as always  8)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 02, 2018, 11:11:54
Why bother staying with metric though imperial sizes are more readily available and you can find one thatís just a tiny bit larger than the 6 mm
1/4Ē

You're right, that makes more sense.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 02, 2018, 11:13:07
Just use Heli-coil or Time-Sert and keep the thread stock.

That is absolutely an option as well
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 02, 2018, 11:18:39
You're right, that makes more sense.

I've done this a few times. The helicoil is better in that it keeps the oem bolt, but something like this your not likely to be changing that bolt out ever again so do the cheaper easier solution. I have one fork oil drain bolt I have done this on for my GL so I always do one fork at a time to drain oil so I don't mix them up by accident.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 02, 2018, 11:23:10
Pretty sure you just nailed it.  There was some kind of switch set-up above the kick stand which I removed, thinking doing so would then bypass the kick stand safety switch.  Not thinking that removing it entirely would break a circuit.  I'll reinstall the switch and plug the thing back in, see what gives.  Thanks for the insight as always  8)

Guaranteed this is the issue. The clutch switch will allow you to start clutch out in neutral. clutch in, in gear. i.e. stalled while riding but the kickstand switch overrides it if you put it in gear it kills the motor. You can easily by pass it. If I get a few minutes I'll look and tell you what wires you need to connect to do it.  I did something similar on my KLF185 to bypass the neutral switch as it was bad and hard to get at to replace.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 02, 2018, 11:54:12
Guaranteed this is the issue. The clutch switch will allow you to start clutch out in neutral. clutch in, in gear. i.e. stalled while riding but the kickstand switch overrides it if you put it in gear it kills the motor. You can easily by pass it. If I get a few minutes I'll look and tell you what wires you need to connect to do it.  I did something similar on my KLF185 to bypass the neutral switch as it was bad and hard to get at to replace.

You should move house mate.  Maybe to, I dunno, Montreal?  Plenty to do here, and always a big question mark hovering over my garage if you ever get bored.  See?  I got it all figured out.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 02, 2018, 11:58:52
LOL, I know, all my buddies who wrench are all 4-500 KM away from me, most 1000+. Luc whom you met does a little but not like the folks on here.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 02, 2018, 13:41:13
Dude it was the kick stand switch.  Plugged it back into the harness and it's off to the races.  First blat down the alley and the grin is good
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 02, 2018, 13:58:23
Nice, I thought maybe you had cut it out and needed to bypass. much easier just to put it back LOL.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 03, 2018, 10:32:59
With the kick stand switched re-connected the bike starts, and gets into gear no problem.  No quite no problem but I think that's because of a dirty connection somewhere.  I'll need to take the starter switch apart (or maybe some other switch) and clean it up.

Never mind that, a mate came over yesterday and we took the bikes out for a 35km jaunt around town.  First ride, both of the year and for the reborn KLR.  Felt great to be back in the saddle, and the bike ran really well.  Couple of hiccups (both the taillight and headlight blew out, and the bike stalled a few times) but hopefully nothing I can't sort out.  The exhaust sounds amazing have to say - not too obnoxious at all but a million times better than stock.  Stock can develop the infamous KLR "tweet" which - although somewhat remediable with a flathead screwdriver and a couple of whacks with a mallet - is a shit sound for any vehicle, let alone a big thumper.  This Lexx takes care of all that.

Need to find out what caused the stalls (hoping it was a gas situation - there's not much in the tank), and the short in the lighting, but all in all couldn't be happier.

 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 03, 2018, 10:41:53
Nice Jimbo, Not too far from my first ride here. Salt is almost gone, one more good rain, although they are calling for freezing rain tomorrow which may make them salt again. Did the fuses blow or the bulbs?  Bulbs popping can mean you have a RR issue with too much juice going to them, fuses is usually a short to ground someplace. You can test the RR with a meter to see, shouldn't allow any more than 15ish volts out if working.  Also can look for a short in the wires with it, set for continuity and put the prongs at each end of the wire between plugs/connectors then wiggle the wire around and see if you lose continuity.  if you do fix that wire.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: SONIC. on Apr 03, 2018, 10:44:52
Congrats on the first ride, that's always a great feeling.
Like Mike said, I'd look at the regulator if you're blowing bulbs. Too many volts and POP.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 03, 2018, 10:52:25
I remember the same thing happening with my old V Star but don't remember exactly how to check the RR.  I've got a multimeter - what setting should I put it to and where exactly do I check? 

Funny, a mate and I were just talking the other day about rectifiers and regulators blowing.  Well, not funny but man - ironic timing
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 03, 2018, 11:07:17
Set it to volts DC, find the + hot lead that comes out usually headed to battery, attach the + lead, ground the - and rev the engine and watch the meter, it should top out at 15-15.5 volts dc, if it climbs past it's bad.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 03, 2018, 11:17:16
I know all the lights were working fine before the rebuild - think it may have something to do with fuses/connectors?  Who knows, right...

I'll definitely check the RR, and like my mate says - do all the easy stuff first. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 17, 2018, 10:01:17
Well it's official sportsfans...El Verdito is running but running pretty rough.  I'm not surprised given all the mods I made (carb rejetting, engine over-bore, airbox and exhaust), but this is new ground for me.  I'll pull the spark plug and will report back on the state of that, but the carb I'm thinking is going to need some well considered tinkering.  I've heard you guys talking about tuning carbs but I'm not sure where to start.  There is also an exhaust leak between the mid pipe and header.

Weather has gone totally tits up so can't see much riding doing in the immediate future.  So rather than staring blankly at the bike I made this over the weekend -

(https://i.imgur.com/mPOEUMr.jpg)

- one on the left is finished and the other needs cleaning up.  Somewhat challenging - did them freehand and cut out of stainless with a dremel and a lot of filing.  I like doing this kind of thing, which is good because they take ages.

Here's where they'll go -

(https://i.imgur.com/JfITIam.jpg)
 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Apr 17, 2018, 10:19:16
Very cool. 

First, sort out the exhaust leak.


Basically, with tuning you want to make marks on your handle bars for each 1/4 throttle with tape and marker.  Figure out where it's acting up and determine if you're dealing with lean or rich.  Then adjust accordingly.  I'm way oversimplifying, but essentially different parts of your carb control different parts of throttle.  RPMs have little to do, except vacuum on the idle circuit when you go too high on the idle adjust.  I try to get a baseline on idle adjust and air mix, then work from there with jets. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 17, 2018, 11:15:49
Oversimplifying is fine by me Irk!  Thanks man, this helps me get my head around what needs to be done and the processes involved.  I'll start with the exhaust, and pull the spark plug - it was in good shape before my trial rides so I'm thinking it should give me some indication of the lean/rich situation.  I've put 80 kms on the bike since the rebuild.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 17, 2018, 11:33:04
Pulling the plug after a ride will give you a little info but not much, it will indicate overall rich/lean but not where in the carb/throttle settings is it off. Start with a clean plug, fire the bike up and let it idle until warm and pull the plug and look at it, if not right, adjust the pilot settings, if good, put it back in and then go do plug chops.  Mark the bar in 1/4's for throttle position so 1/4 turn, 1/2 turn, 3/4 turn full. Get on a quiet street you can hold a throttle position for a steady min or 2. Bring your plug wrench and a couple of plugs. Ride at 1/4 throttle first steady for a KM or 2, pull clutch, hit the kill and pull over, pull out the plug and look, if all golden brown and good, pilot circuit is good. Next do the same at 1/2 throttle, if good, do 3/4, if good do WOT. My guess is you'll foul or lean out before WOT, there is a great chart I'll see if I can find that correlates throttle position and plug condition to know what to change, i.e. screw mixtures, jet sizes, needle position etc.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Apr 17, 2018, 11:39:31
This site is pretty good:
http://www.dansmc.com/carbs2.htm
http://www.dansmc.com/sparkplugs1.htm
http://www.dansmc.com/spark_plugs/spark_plugs_catalog.html
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Apr 17, 2018, 11:51:15
Thanks gents, that's really helpful.  I'll do that - taking the bike to the parking lot at Canadian Tire will spare the neighbours the joys of me thrashing the engine in my garage.  I'll check out those websites Mike and arm myself with as much info as I can get hold of.  Daunted?  Not I.  I've got shiny KLR badges now.  I got this.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Apr 17, 2018, 12:46:45
Jet rich and work your way down.  Carry a spare plug wrench in case you foul the plug and it stalls.  Have you found someone to give you ballpark jetting to start with?

Your badges look great, like the rest of your bike.

Brian
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 01, 2018, 19:30:36
No progress on the carb sadly, but did sort out the exhaust leak with the help of a well positioned Granville Island Pale Ale can to shim the gap and some hi-temp silicon gasket.

Got the badges finished up and bolted into place -

(http://i.imgur.com/GiEi8PR.jpg)

(http://i.imgur.com/0g2mpRn.jpg)

Once the weather clears up - hopefully later this week - me and a mechanically minded mate are gonna get the carb dialled in. Then El Verdito should pretty much be open for business


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 01, 2018, 21:15:35
Looks awesome.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 01, 2018, 22:36:09
+1

Looks stunning!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on May 02, 2018, 01:03:28
Gorgeous!  You certainly have a great eye to make a beautiful bike.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: doc_rot on May 02, 2018, 04:03:45
that badge turned out nice
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 02, 2018, 08:29:00
You're really classing up that old KLR, looks great Jim.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on May 02, 2018, 09:21:31
Looks good jimbo. Im ready to not be able to see that decal for all the mud caked on it here soon!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 02, 2018, 10:52:20
Thanks a lot gents, really appreciate the good vibes.  Now that the exhaust leak is sorted, really hoping to get to the slightly more pressing matter of the carb, maybe this eve if the stars align.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 14:23:35
Gents (and any gals out there if there are any and we hope there are) ok, carb time.

Thanks for bearing with me - those that followed along the CB750 will be familiar with my tsunami of questions.  Fired up the bike last night to see what gives - weather has done to shit again so right now I'm trying to get everything ready for when things clear up.  It's idling really, really rough.  From my understanding I need to get a baseline - by that do you mean I need to get the idle right first?  I know a rough idle can be caused by a vacuum leak (like a tear in the rubber boot or poor fitment of the carb body to the airbox/cylinder) but I'm sure those parameters are in good shape.  What would be the next step into dialling the idle in?  I've played with the big exterior bolt which adjusts the idle (well, it adjusts the throttle cables which in turn adjusts the idle) but with no real success.

Ask me anything you need to know to get a better idea of what's going on, and I'll do my best to answer.  Pretty sure getting the idle right is a good place to start on when trying to get the carb dialled in.
Title: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 03, 2018, 14:52:39
Gents (and any gals out there if there are any and we hope there are) ok, carb time.

Thanks for bearing with me - those that followed along the CB750 will be familiar with my tsunami of questions.  Fired up the bike last night to see what gives - weather has done to shit again so right now I'm trying to get everything ready for when things clear up.  It's idling really, really rough.  From my understanding I need to get a baseline - by that do you mean I need to get the idle right first?  I know a rough idle can be caused by a vacuum leak (like a tear in the rubber boot or poor fitment of the carb body to the airbox/cylinder) but I'm sure those parameters are in good shape.  What would be the next step into dialling the idle in?  I've played with the big exterior bolt which adjusts the idle (well, it adjusts the throttle cables which in turn adjusts the idle) but with no real success.

Ask me anything you need to know to get a better idea of what's going on, and I'll do my best to answer.  Pretty sure getting the idle right is a good place to start on when trying to get the carb dialled in.

I usually start with full throttle.
Changing the main jet will affect all the other throttle positions to an extent and the main jet is the only way to change the ratio at wide open.

When you have full throttle worked out then you can worry about your mid range with the needles and needle jets. Finally when all that is taken care of, worry about the idle.

If you shoot some starter fluid around the boots you can listen for an air leak and rule that out real easy.
If it runs better with the choke/enricher on then sheís lean.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 03, 2018, 15:51:56
Get the bike running to operating temp- at least 10 minutes.  Once it's hot, turn the idle screw to the lowest setting it will go without stalling.  That's usually 700 - 800 rpm.  Turn the air mix screw in until the idle drops, then out until it drops again, then turn the screw halfway between those points.  Then set your idle where you want it.  On my airheads, because of their charging system, I tend to set idle higher (1100 - 1200).  Most of my thumpers idle around 1k.  You should be no less than one turn and no more than three turns on the fuel/air mix if the idle jet is right.  Once your idle is set, then mark your throttle into 4 quarters and see where it's messing up. This is a good general guide to help you find the tune...

(http://103.18.108.161/~thewater/mikunioz/wp-content/uploads/2015/02/pilot_jet_intro.gif)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 03, 2018, 16:00:06
What irk said. You have 2 things that control idle. The knob thay opens the butterfly and the mixture screw which either adds more or less air as it in turned or fuel. The bike being fully warmed up is very important too. Changing idle on a cold engine will just be way off again when warm.  What Farner said is true too, starting at full throttle runs and getring the main jet right is the easiest one. The in between setting are a little harder but you'll get them.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 16:01:55
Tidy, thanks gents, really helpful in getting this job off and running.  The air mix screw - is that the pilot (idle) mixture screw?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 03, 2018, 16:06:09
That's it.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 03, 2018, 16:06:19
Yep. Im not sure what kind of pilot you have. They control the pilot/idle circuit, some increase or decrease the air in circuit whike others increase or decrease fuel. Whichever you have the circuit has a fixed amount of one whike the screw changes the other to change air fuel mix with throttle 99% closed
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 16:11:17
Excellent, I'm getting somewhere.  I'm gonna need one of these whatnots to get to the pilot screw, right?

(https://i.imgur.com/cNlVdWO.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 16:16:11
You should be no less than one turn and no more than three turns on the fuel/air mix if the idle jet is right.

Irk, the idle jet - is that the same as the idle screw? Or is the idle jet the same thing as the pilot jet? 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 03, 2018, 16:37:07
(http://www.dotheton.com/gallery/1732-030518143455.gif)

This is the carb Pilot is on bottom 16014. Its likely a flat head and carefuk screwing it in you can break it if you over tighten it. You won't need the fancy screw driver
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 03, 2018, 16:38:44
also the description calls it pilot air screw so it increases or decreases air.

https://www.bikebandit.com/oem-parts/2000-kawasaki-klr650-kl650a/o/m149578#sch65997
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 03, 2018, 18:55:53
Which would suggest that three or more turns out and the idle jet is too rich, or less than one turn in and the idle jet is too lean.  Anywhere in-between and your idle jet is good.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 03, 2018, 19:04:12
Good point Irk
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 19:10:42
Is the idle jet the same thing as the pilot jet?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 03, 2018, 21:51:24
Is the idle jet the same thing as the pilot jet?
Yes.  Did you change anything?  If not, than really you're just adjusting the air screw and idle and good to go.  Not likely much else will change.  No reason to go into all this other stuff unless you've upgraded the carb or something.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 22:20:31
Dude, Iíve changed everything

Bored the cylinder to 685, Stage 2 DynoJet kit in the carb, modified airbox and new Lexx exhaust.

Oh, KLX front fender, new bars and grips and a bunch of other shit but hopefully thatís not fucking anything up


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on May 03, 2018, 22:39:41
You'l never get the carbs set up properly with new grips, put the originals back on.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 03, 2018, 22:51:24
What size jets were in there originally?
What sized jets are in there now?

Have you figured out if itís rich or lean yet?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 23:13:58
You'l never get the carbs set up properly with new grips, put the originals back on.




Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 23:20:02
What size jets were in there originally?
What sized jets are in there now?

Have you figured out if itís rich or lean yet?
Rich mate, very rich. Iíll post up a pic of the plug - blacker than a stack of black cats in a coalmine.

Not sure about the jet sizes but will check


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Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 03, 2018, 23:24:30
(https://i.imgur.com/EB0VtWx.jpg?2)

Blacker than Black Sabbath - Black Sabbath with the lights out and very thick curtains on the windows at midnite with no moon. And a bit foggy.

Blacker than - you get the picture.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 04, 2018, 07:04:49
(https://i.imgur.com/EB0VtWx.jpg?2)

Blacker than Black Sabbath - Black Sabbath with the lights out and very thick curtains on the windows at midnite with no moon. And a bit foggy.

Blacker than - you get the picture.

Is it a dry black?

If you let the plug sit for a while after you pull it out does it dry off? If it stays wet then youíre sucking oil in somewhere.
Hopefully itís just pig rich
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 04, 2018, 09:48:43
It's a dry black, yeah.  I mean this thing is caked.  Also blowing belches of black smoke from the exhaust when I twist the throttle.  A bit wet on the threads but I think just residual.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 04, 2018, 16:31:20
Did you enlarge the slide lift hole when you installed the Stage 2 kit?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 04, 2018, 16:35:11
I did, yeah
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 04, 2018, 16:41:11
That stage 2 kit and enlarging the slide lift hole should have your carb right.  There usually a pre-packaged kit set up for the mods.  Unless there is an issue on the air side of things and not the jetting.  That sooty is way off on the mix. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: JSJamboree on May 04, 2018, 16:41:36
We all know all bikes are different, but with the KRZ/KLX/DRZ whatever when you go big bore you have to drop down a size in mains and slow jet
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 04, 2018, 16:43:10
Down size when the carb bore stays the same to handle the extra velocity pulling more fuel.  I usually go up on carb bore with a big bore on thumpers.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 04, 2018, 16:46:16
That stage 2 kit and enlarging the slide lift hole should have your carb right.  There usually a pre-packaged kit set up for the mods.  Unless there is an issue on the air side of things and not the jetting.  That sooty is way off on the mix.

I was wondering about that.  I didn't really do much to the filter itself, think it would benefit from a good clean?  It's a foam filter - is there a proper way to clean those things?

Was also suggested that pulling the filter out completely as a test may point to whether or not the filter is too restrictive/dirty.  Run the bike without the filter, get more air into the carb and see if it runs better.  What do you think?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 04, 2018, 19:45:48
I was wondering about that.  I didn't really do much to the filter itself, think it would benefit from a good clean?  It's a foam filter - is there a proper way to clean those things?

Was also suggested that pulling the filter out completely as a test may point to whether or not the filter is too restrictive/dirty.  Run the bike without the filter, get more air into the carb and see if it runs better.  What do you think?


I wash mine with some warm water and dawn dish soap.
You want to wash out the oily crap, then rinse, let dry and re-oil with filter oil. Pull it out and see how she runs.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 04, 2018, 19:47:06
Is filter oil a specific kind of oil or is there something else I can use?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 04, 2018, 19:58:26
Is filter oil a specific kind of oil or is there something else I can use?

Usually in a spray can, itís application specific as i think itís a little clingier than regular engine oil.

Nothing to say you couldnít use regular oil but i tried once and it drips out and makes a mess. Might not be too bad in an airbox though.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 04, 2018, 20:07:51
Gotcha, that makes sense - thick clingy oil to catch all the dust and shite going through the airbox.  I'll pull the filter and haul the old girl round the block a few times, see what gives.  Looks like the apocalypse outside, I swear it's raining upwards.  I'll leave the ride till tomorrow, 20 degrees and sunny on the forecast.  That's more like it.

But then again I have been invited to a barbecue which inevitably means that the weather will go to shit.
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 06, 2018, 10:22:16
Ok. Pulled the filter out the airbox and went for a ride yesterday.

Damn.

Different bike. Throttle response way smoother, much less boggy, just way more fun. Really felt much better.

So today Iím going to properly clean the filter (I bought some mineral spirits yesterday - will that do it?) but donít have the right filter oil, Iíll pick some up next week.

Iím also going to pull the carb and switch out the main jet for a smaller size. Letís see.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 06, 2018, 11:30:32
Dawn dishsoap and water. Let it dry. Ct sells kn filter oil spray and a cleaner but dawn works awesome and is cheaper
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 06, 2018, 11:33:35
So I shouldnít use mineral spirits? Just wash the filter with dawn? How about oiling the filter afterwards?


Sent from my iPhone using DO THE TON
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 06, 2018, 12:31:30
Yep use dawn to ckean then get filter oil. Ct has kn and it works well. It red too so you can see how much you put on.  The other option is 2 stroke oil. It works. Regular motor oil can worj too in a pinch.  Apply and if you can squeeze out excess thats the best. Ie a foam filter. But a cotton wire like a kn you need to spray and let drip then put back.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 06, 2018, 12:44:59
I use Fab1 on all of my filters, K&N and Uni. 

https://www.amazon.com/Maxima-70-799202S-Air-Filter-Maintenance/dp/B00TO61SKM/ref=sr_1_1?ie=UTF8&qid=1525621480&sr=8-1&keywords=fab+1+air+filter+oil&dpID=51nIxDepNqL&preST=_SY300_QL70_&dpSrc=srch
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 07, 2018, 10:25:25
Thanks for all the help with this gents, it really helped me out once again.  Took the bike out again without the filter just to confirm how everything ran and sounded, then got to work on the carb.  Turns out you can get to the jets while leaving the carb in situ -

(https://i.imgur.com/pxp99jD.jpg)

It means removing a bunch of crap from the other side (namely starter relay assembly, some hoses need to be rerouted and the gas tank shimmed up by 3-4") but it's doable.  Switched out the 155 jet that I'd previously installed for a 150 -

(https://i.imgur.com/ciIqlIp.jpg)

and buttoned it up again.  You have to be careful that the dowel pin holding the floats in place doesn't dislocate but again, doable.  Pulled the plug, gave it a good clean with a wire brush and carb cleaner, and once everything was back where it should be I went out for another ride.  Big difference - so much smoother, crisper and with far better throttle response.  Still had a fair amount of black exhaust when I cracked the throttle, but it's maybe significant that the air filter was not installed.  I'm hoping once it's cleaned and reinstalled that the air/gas mix will balance out a bit better.  I'll also pull the plug again and see what it looks like (didn't have time last night).

Overall - to anyone reading this that has a thumper and is staring down the barrel at carb work - it's not as hard as I made it out to be.  Especially as the jets can be accessed (on this KLR anyway) with them still in the bike.

Edit - On second thoughts, once the air filter is installed I'm now thinking the bike will run richer if anything and therefore the black exhaust probably won't die down.  What would you suggest the next step?  Dial down the jet - or play with the needle shim?  Or the air mixture screw?

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: SONIC. on May 07, 2018, 10:43:44
http://advrider.com/index.php?threads/help-me-jet-my-klr-685.768908/

From that read it looks like most of these 685's are running 142-145 mains.

From ADV Rider:

"I've used my A/F meter (wide band O2) on doz of KLR's. I generally end up with the following final settings using KLX needle. Folks report they average 47-50mpg in mixed riding.

KLX needle 2nd clip
142.5 main jet
7/64 drilled slide
Fuel screw adjusted for max rpm's (generally 1.75 to 2.25 turns out)"
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 07, 2018, 10:48:49
Jim, what is the stock jet for the bike? rule of thumb generally is +1 step  for more open exhaust, and likely +1 step for the larger piston. I looked at BB but it has various #'s from 142-150 with 2 step increments, so if your bike started with a 142 +2 would be a 146 so my guess is you'll end up there or maybe a 148 with the snorkel removed. 150 may be too rich.  But if you are using aftermarket jets the sizing steps may be different from oem.  You'll need a conversion chart.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 07, 2018, 10:50:51
Thanks for the link, that's great info.  Appreciate it mate - will investigate
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 07, 2018, 10:52:51
Cheers Mike, I think you already hooked me up with the conversion chart so it should be pretty easy to figure out what size the DynoJet jet is compared to OEM.  I'll have a look later, thanks fella
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: SONIC. on May 07, 2018, 10:59:07
Yezzir.
ADV Rider is a ridiculous treasure trove of information it's just so huge it can be a PITA to sort through it.

I've never messed with a dynojet kit (i like to stick OEM on carbs) but if it's as rich as it seems if it were me I'd toss the stock bits back in and see what you get, then maybe bump the main up a couple notches. Stock shouldn't be lean enough to hurt anything with testing.
Carbs are a tricky bitch, sometimes you make change after change only to find out that stock works best, or that you needed to actually drop down a jet size instead of go up. I fought a 400F forever until someone finally told me to actually drop the jets a size and bam right on.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 07, 2018, 11:03:41
Yezzir.
ADV Rider is a ridiculous treasure trove of information it's just so huge it can be a PITA to sort through it.

I've never messed with a dynojet kit (i like to stick OEM on carbs) but if it's as rich as it seems if it were me I'd toss the stock bits back in and see what you get, then maybe bump the main up a couple notches. Stock shouldn't be lean enough to hurt anything with testing.
Carbs are a tricky bitch, sometimes you make change after change only to find out that stock works best, or that you needed to actually drop down a jet size instead of go up. I fought a 400F forever until someone finally told me to actually drop the jets a size and bam right on.
No kidding?  Drop a jet size huh, who'd'a thunk it.  Maybe I'll end up down that route too.  The good news is that accessing the jet is really easy on this KLR, and I bet if I rotate it the other way I could probably access the slide and needle too if necessary.

I'm a member of ADV Rider but yeah, there's a lot of wading to be done over there.  I should definitely dig deeper though, you're right - there's a ton of great info there.  Thanks again man
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 07, 2018, 11:14:38
The reason for dropping a jet size is because you went up in bore, but remained the same size on the carb.  There is significantly more vacuum pulling through the venturi, which is pulling more fuel.  Making the carb slide hole more open is supposed to reduce some of that effect for the main.  It's also possible the vacuum is pulling the main up early, so you are running off the pilot and main together and too early.  If you open up the exhaust and airbox more, or forgo the airbox altogether for Uni filters, then it's possible you would have to do the opposite.  If you're trying to do all of this just in the garage at idle on center stand, then you may not get the right information.  You'll really need to ride it to figure out your mid and upper range on throttle.
Title: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 07, 2018, 11:21:34
No kidding?  Drop a jet size huh, who'd'a thunk it.  Maybe I'll end up down that route too.  The good news is that accessing the jet is really easy on this KLR, and I bet if I rotate it the other way I could probably access the slide and needle too if necessary.

I'm a member of ADV Rider but yeah, there's a lot of wading to be done over there.  I should definitely dig deeper though, you're right - there's a ton of great info there.  Thanks again man

When you free up the air passages you reduce the amount of vacuum required to suck x amount of air through the carb, this means less fuel gets sucked in and you need to jet richer for intake/exhaust mods. (usually)

The big bore kits on the other hand will increase the vacuum.
This causes both more air and fuel to get sucked in. In certain situations itís likely that the fuel flow increases more than air flow and you could end up rich even on stock jetting. Itís all about the Bernoulliís principal.

Edit: IRK beat me to it
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on May 07, 2018, 12:18:41
You guys explain so nicely the effects i experienced when boring out the xs750 and xs11. Since i dont know shit about physical principles it felt odd needing to drop the needle to the bottom on the xs11, and go back to stock jets. Might even have to drop a size before its 100%
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 07, 2018, 22:34:01
Thanks again for all the help and explanations, really gives me more understanding of how the carb actually works.  Didn't get round to playing with the jet today but did figure out that the jet I have in there now is a DynoJet 150 (down from 155).  That's the equivalent of a Keihin 165.

Did however get myself a can of PlastiDip and turned those butt ugly white side covers a rather splendid black -

(https://i.imgur.com/mxOlMKn.jpg)

Never used PlastiDip before but I like the texture when it dries.  Hopefully tomorrow I'll have time to get back to the carb - I'll switch the jet for a smaller size, clean that filter (I followed your lead Irk and ordered the foam filter cleaning/oil set you suggested) and see what gives.  Getting closer.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 08, 2018, 08:26:02
Plasti-dip is great stuff.  165 is way large and likely your rich issue. I'd get a Keihin 150 and try that as it was the large side of stock on the BB parts listing.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 08, 2018, 09:34:28
I'll try that - the DynoJet kit came with a bunch of main jets so I'll keep dialling it down until I lose the cloud of black smoke from the exhaust and the plug stops fouling.

Speaking of which, does anyone have an idea why the bike occasionally stalls?  It'll do it pretty randomly but usually when I'm decelerating.  Coming up to a stop sign, traffic lights. that kind of thing.  But it can also do it when I'm just going down the road.  Happened about 5 times in 15 minutes yesterday.  I'm still keeping the bike local so I'm not at speed when it happens, but it's a bit unnerving - and I look like a right wally when it happens next to a beer terrace full of people.  Not a cool look at all.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 08, 2018, 09:37:45
I could be the rich condition fouling the plug enough to make it quit. but it sounds more like a bad connection in your ignition circuit. I had an old fuse that would randomly disconnect and kill the bike only to reconnect seconds later and start back up. Also a lose ground can cause the same thing. Check all your wires for routing/chafing connections etc.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 08, 2018, 09:38:56
If you're fouling plugs then it will cause intermittent stalling and starting.  The carbon is grounding your spark, but it's not necessarily consistently happening.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 08, 2018, 09:42:35
Yeah man, I think you nailed it.  The start button/kill switch assembly is a bit on the iffy side.  Sometimes the bike fires right up, sometimes I have to hit the throttle/mirror/starter button assembly in the hope it'll jog something.  I think there's a loose connection in there somewhere - think that could cause the bike to cut out while it's running?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 08, 2018, 09:45:26
I would fix your fouling plugs first.  That will cause the conditions you're experiencing.  You're going to be chasing ghosts when you have a glaring problem already.  Poor spark will cause fouling too, but you don't know yet whether your jetting is right.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 08, 2018, 09:45:55
Yep, if the kill switch is on the same handle and something is lose it could cause the issue for sure. Look for a broken solder joint in the housing. or bad corrosion etc.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 08, 2018, 10:00:35
Thanks gents - I'll look into both suspects and hopefully find the guilty party.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 09, 2018, 10:36:06
Got to the carb again yesterday evening, switched out the DynoJet jet 150 (that's a Keihin 165) for a 140 (Keihin 152) - still belching black smoke from the exhaust.  I've only got one jet size left in the kit and that's a 136 (Keihin 148).  Hoping that'll at least dial down my exaggerated contributions to global warming.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Brodie on May 10, 2018, 08:31:22
Did you put the air filter back in yet?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 09:40:22
Actually Brodie, no, not yet.  I ordered a foam filter cleaning and oil set which arrived yesterday but I didn't get round to cleaning the thing yet.  I was thinking however that once I install the filter the mix would only get slightly richer if anything.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 09:50:43
Another thing I noticed - while I was waiting at a traffic light yesterday the engine's idle slowed, slowed and then cut out.  Almost like I'd drained the gas, but I hadn't.  Put the bike into neutral, hit the starter and it fired right up.  Weird to me, but hopefully not to you guys!  Carb?  Lack of air filter?  Plug?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 10, 2018, 10:00:14
Slowly fouling plug, still too rich on idle?  did blipping the throttle do anything to help?  Get the bike fully warmed. put in a new clean plug, fire it up and let it idle for 2-3 min if it will them kill it and check the plug, if its all sooty your still to rich on idle.  Put air filter back first though and if it won't idle you'll need to adjust the pilot and or throttle position knob to get it to stay at idle.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 10:08:48
Ah, too rich on idle.  Makes sense when you spell it out mate.  I'll clean and oil the filter, follow the steps you explained and will report back.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 10, 2018, 10:12:49
If it's running out of fuel, it's going lean.  It will often raise in idle, then cut out.  If you're puffing black smoke, as you know, it's rich.  Probably losing spark as the plug carbon up. 

As far as the air filter, if you're pulling more air with the CV, you could be pulling more fuel.  You may be raising the needle too early and have it running on two circuits.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 10:15:46
If it's running out of fuel, it's going lean.  It will often raise in idle, then cut out.  If you're puffing black smoke, as you know, it's rich.  Probably losing spark as the plug carbon up. 

As far as the air filter, if you're pulling more air with the CV, you could be pulling more fuel.  You may be raising the needle too early and have it running on two circuits.

What would be the remedy in that case Irk?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 10, 2018, 10:17:39
It's speculation at this point, but if what I'm suggesting is the case then the air filter will sort it.  Odd things happen.  Best to test when all conditions are normal.  Air filter, exhaust, idle, etc.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 10:26:27
Got it, thanks gents.  Odd things happen indeed.  Like just the other day I was in the post office and bumped into a mate I hadn't seen for a while.  While we were shooting the shit a 20-something-year old chick politely interrupts us and says "Excuse me guys, I saw you just mailed a letter and I was wondering if you could show me how to do it?"

She went on to tell us she'd never mailed anything.  Ever.  And had no idea where to write the address or stick the stamp.  Holy shit.  What a world.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 10, 2018, 10:35:28
Speaking of mail, I need to go get a card for me mum and mail it today for mothers day, shit, gonna have to pay for next day dammit, I'm a horrible son.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 10:35:36
Or how about this for odd.  I was sitting on a plane once with my brother, flying from Delhi to Goa.  I was in the middle seat, brother in the aisle - window seat was empty.  Don't ask me why.  All of a sudden there was a sneeze, and suddenly someone was sitting in the window seat.  What the deuce.  We christened him Claypole (anyone reading this of a certain age from the UK will get the reference) and never saw him again after that flight.

Except once.

I fell down a mine shaft about a month later in the middle of nowhere in India with a mate who got knocked unconscious.  I shouted for help and after a while, guess whose head peered down at us from the mouth of the hole?  Claypole.  Turns out he was a fully qualified nurse, hauled us out and made sure we were ok.

Odd things.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 10:42:16
Speaking of mail, I need to go get a card for me mum and mail it today for mothers day, shit, gonna have to pay for next day dammit, I'm a horrible son.

At least you remembered.  Being from the UK, my Mothers Day is about a month earlier than here in North America.  I cock that one up regularly.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on May 10, 2018, 10:57:30
Or how about this for odd.  I was sitting on a plane once with my brother, flying from Delhi to Goa.  I was in the middle seat, brother in the aisle - window seat was empty.  Don't ask me why.  All of a sudden there was a sneeze, and suddenly someone was sitting in the window seat.  What the deuce.  We christened him Claypole (anyone reading this of a certain age from the UK will get the reference) and never saw him again after that flight.

Except once.

I fell down a mine shaft about a month later in the middle of nowhere in India with a mate who got knocked unconscious.  I shouted for help and after a while, guess whose head peered down at us from the mouth of the hole?  Claypole.  Turns out he was a fully qualified nurse, hauled us out and made sure we were ok.

Odd things.

I nominate this thread for DTT Story of the Month.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 10, 2018, 10:58:30
I nominate this thread for DTT Story of the Month.

+1. and if you hadn't made the comment about mail I'd have cocked up the M-Day card so thanks for that.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 11:29:42
I nominate this thread for DTT Story of the Month.
That story doesn't quite end there.  We were travelling with this guy we'd met in Thailand with the rather uncommon name Jesus.  He looked the part too.  But on a later flight that day was a Japanese friend of mine called Masya.

So we arrived at Goa airport and told anyone that would listen that Jesus was here, and the Messiah was coming.  Remarkable how we avoided the loony bin. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 18:53:12
Ok well that stuff worked...

(https://i.imgur.com/0vUu9IR.jpg)

Cheers Irk for the suggestion - Maxima Air Filter Cleaner does exactly what it says on the tin.  What it doesn't say on the tin is that your better half will lose her shit if you spray it in the kitchen sink, like Totally. Lose. Her. Shit.  So a word to the wise - if you value your marriage or any kind of meaningful relationship, don't spray this stuff anywhere near a trout filet.

Will wait till it dries, oil the thing up with the can of Fab1 I also received and get it out of the kitchen and into the bike.  Where it belongs.  Although it looks great on the kitchen table.  "No it fucking doesn't!".  No, you're right of course love.  I'll get it out of there.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 10, 2018, 19:02:15
Thatís one hell of a B/A photo
Nice table btw!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 10, 2018, 19:58:00
Nice table btw!
Floorboards salvaged from a 300 year old building.  It's a sobering thought while I'm working on my cornflakes - where I now eat, some Dickensian whippersnapper grumbled over peeling turnips and being shoved up a chimney. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 11, 2018, 10:51:27
Oiled up the filter and installed the thing last night, then took the old girl for a blast round Montreal.  She seems to go pretty well but still blowing huge belches of black smoke from the exhaust.  Seems like it hasn't diminished at all despite going down a fair few jet sizes.  I have one more DynoJet left in the kit (a 136 I think, equivalent of a 148 Keihin) and that's it.  I think in fact that may be smaller than the stock jet I took out originally but I'm not sure.

Haven't check the plug yet, but I will.  If it's not the jet, could it be the mixture screw, or maybe the needle?  Pretty sure this question must have been asked a thousand times on this forum, thanks one and all for helping a guy out.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 11, 2018, 10:58:11
Sheís not sucking oil in somewhere is she?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 11, 2018, 10:58:37
Yeah, very likely chance it's the mixture screw.  I'm pretty sure some of us were saying to get that right first.  That's what I was saying, at least.  Once you get that right, then you get the idle right, then you go into jetting, needle valve and needle.  If you can't get the mixture right during idle, then you know your pilot is wrong.  Reading back a few pages, you are only changing one jet, from what I see.  That's your main jet, which only covers the top end of your throttle.  The needle covers from about 1/4 throttle to 3/4 throttle. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 11, 2018, 11:06:34
Sheís not sucking oil in somewhere is she?
That did cross my mind.  But this smoke is black, really black, not blue.  I did put a new piston in with new rings (which needed gapping) - I've never done that before so although I think I did it right I guess there's always room for, well, for not doing it right.  But I'm pretty confident.  New gaskets, correct torque specs when rebuilding the engine - I dunno man, gut tells me it's not oil.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 11, 2018, 11:13:22
Most likely not oil. your plug would look different from oil fouling. Most likely the mixture. Did the dynojet kit give you a pilot - slow jet that you changed? If so put the original back in that spot and get the mixture and idle set correctly. Irk splained that a few pages back, also you can google it specific for the KLR. There are some base settings to start from then adjust from those to get it right.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 11, 2018, 11:15:04
New rings need to be seated.  Not uncommon at all to smoke quite a bit on fresh rings.  Seat by quickly hitting full throttle, letting off, down shifting and engine braking down hills.  Back and forth and repeat.  Basically putting pressure on both sides of the rings to get them to seat.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 11, 2018, 11:18:07
Yeah, very likely chance it's the mixture screw.  I'm pretty sure some of us were saying to get that right first.  That's what I was saying, at least.  Once you get that right, then you get the idle right, then you go into jetting, needle valve and needle.  If you can't get the mixture right during idle, then you know your pilot is wrong.  Reading back a few pages, you are only changing one jet, from what I see.  That's your main jet, which only covers the top end of your throttle.  The needle covers from about 1/4 throttle to 3/4 throttle.
Sorry guys and thanks for bearing with me on this.  You're right.  I need to take a step back and really get my head around what it is exactly I'm going.  Need a better understanding of the principals and workings of the carb, then I'll know what it is exactly I'm trying to do.  In laymans terms I want to stop the exhaust from heaving out black smoke and the plug from fouling!  But I need to school myself on why it's happening, and the process involved in diagnosing and fixing it.

I need me some schoolin'
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 11, 2018, 11:21:48
No need for apologies, my man.  I think sometimes we're messaging on top of each other too.  So things get missed.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on May 11, 2018, 11:26:13
I'm surprised it even runs and wont bog and die if its blowing all that black smoke. I would suggest dumping all those notoriously inaccurate dynojet bits and put the carb back to stock, jet from there using original jets.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 11, 2018, 11:27:59
I barely understand it too, I like to find instructions for the bike I am working on and follow them to get a base then make the small changes needed to get it running the best it can. For example on the Virago, I found a full set of tuning instructions that included what the baseline mixture setting is, then which way to go leaner or richer from those in the spots needed etc. it's usually something like - screw the mixture all the way in, not too tight or you can damage it, then 2 full turns out fire up bike and see how it idles, then turn in or out until it starts to stall or rev stopping at the amount of turns it idles well.  Always after the bike has fully warmed up.  then plug chops to figure out needle settings and main jets etc.  Question, at what throttle opening does it start belching soot? if it isn't until WOT it's main jet, if in between it's Main and needle if immediately from idle its mixture/needle and main could be fine.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 11, 2018, 11:32:25
I barely understand it too, I like to find instructions for the bike I am working on and follow them to get a base then make the small changes needed to get it running the best it can. For example on the Virago, I found a full set of tuning instructions that included what the baseline mixture setting is, then which way to go leaner or richer from those in the spots needed etc. it's usually something like - screw the mixture all the way in, not too tight or you can damage it, then 2 full turns out fire up bike and see how it idles, then turn in or out until it starts to stall or rev stopping at the amount of turns it idles well.  Always after the bike has fully warmed up.  then plug chops to figure out needle settings and main jets etc.  Question, at what throttle opening does it start belching soot? if it isn't until WOT it's main jet, if in between it's Main and needle if immediately from idle its mixture/needle and main could be fine.
Ha!  Can't tell you how much better that makes me feel!  Forums, YouTube, Clymers and phone-a-friend...the more help I can get the better!  Good info Mike, to answer your question the black smoke belches when the bike is idling and I crack the throttle.  Maybe 1/4, maybe 1/2 but no more than that.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 11, 2018, 11:33:47
Get the bike running to operating temp- at least 10 minutes.  Once it's hot, turn the idle screw to the lowest setting it will go without stalling.  That's usually 700 - 800 rpm.  Turn the air mix screw in until the idle drops, then out until it drops again, then turn the screw halfway between those points.  Then set your idle where you want it.  On my airheads, because of their charging system, I tend to set idle higher (1100 - 1200).  Most of my thumpers idle around 1k.  You should be no less than one turn and no more than three turns on the fuel/air mix if the idle jet is right.  Once your idle is set, then mark your throttle into 4 quarters and see where it's messing up. This is a good general guide to help you find the tune...

(http://103.18.108.161/~thewater/mikunioz/wp-content/uploads/2015/02/pilot_jet_intro.gif)
;)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 11, 2018, 11:36:22
;)

Thanks again man, this is really gonna help.  It's like my wife always says to me - what I'm looking for is always right in front of my face.  Like the time she was in India, and I was standing in front of an open fridge at home, hungry, alone, and unable to find food.  Down the phone and on the other side of the world wife tells me to look on the top shelf, on the right, next to the mayo - packet of sausages.  Damned if they weren't sitting right there.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 11, 2018, 11:44:24
I also think datadavid's suggestion to go back to stock jetting and work from there is spot on.   

I wonder if all people that decide to work on any carburetor should be forced to work on a Holley carb first.  There are so many damn places to adjust those carbs.  You learn really quickly to change one thing at a time, and start from one point early and work your way through the carb until you get the tune right.  It's so easy to get lost in the variables. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 11, 2018, 13:48:51
I also think datadavid's suggestion to go back to stock jetting and work from there is spot on.   

I wonder if all people that decide to work on any carburetor should be forced to work on a Holley carb first.  There are so many damn places to adjust those carbs.  You learn really quickly to change one thing at a time, and start from one point early and work your way through the carb until you get the tune right.  It's so easy to get lost in the variables.

Trial by fire, i like it.
Weed out the weaklings right at the start hahaha.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: SONIC. on May 11, 2018, 17:35:16
I also think datadavid's suggestion to go back to stock jetting and work from there is spot on.   

I wonder if all people that decide to work on any carburetor should be forced to work on a Holley carb first.  There are so many damn places to adjust those carbs.  You learn really quickly to change one thing at a time, and start from one point early and work your way through the carb until you get the tune right.  It's so easy to get lost in the variables.

That's what I said ages ago :D
Go back to stock, jet up or down as needed. Although a lot of people run a big bore KLR without touching the carb.
The big bore will make you likely need to drop a jet, and the exhaust will go up one so you're essentially back where you started :D
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 11, 2018, 20:52:00
Duly noted, thanks for the direction - as soon as I get back from the mother-in-laws then that's what I'll do. 

I did follow your advice - got the bike up to running temperature by riding it around the hood for 15 mins, then pulled the plug and gave it a good clean before replacing it.  Then fired it up again and let it idle for 3 or 4 mins, and then pulled the plug again.  It looked like this -

(https://i.imgur.com/UY2g6qL.jpg?1)

Rich idle, right?  So cleaned it, replaced it and fired up the bike again, turning the idle screw to its lowest setting without stalling.  I had to chop up a screwdriver bit to get to the idle screw but it was still pretty tricky to reach - not entirely sure I achieved a great deal as I kept burning myself on the exhaust.  Still belching black smoke.  But at least I've discovered that the bike is idling rich, so there's that. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 11, 2018, 21:16:51
Okay, don't get offended by this question but is the choke off?  That honestly looks like a plug that's been run a while with the choke on.

I had what I thought was a situation with my airhead.  The thing just went out of sync after I did a bit of work on it.  I went about re-syncing the carbs and rode it around.  It rode okay, but nothing like it was supposed to.  Baffled, I pulled it back in the garage to give it a look.  I had the choke cables disconnected, so I didn't consider the possibility.  Turns out, the right side carb choke must've gotten hit and it was engaged. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 11, 2018, 21:47:16
Dude I literally never need the choke on this bike. Unless something is fucked up in the choke mechanism that Iím unaware of, I never have it on.

That plug got that black in the three minutes the bike was idling. Think the choke might be messed up? I did replace the lever but not the cable.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Popeye SXM on May 11, 2018, 23:22:24
For me the choke being on would explain a lot of your symptoms. Has to be very rich to turn the plug that black. Something is way off for sure. Good luck with it, I hope it doesn't drive you crazy. Tuning carbs can be painful
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 12, 2018, 11:03:06
Tell you what though, went to sleep thinking about the choke and it was the first thing I thought about when I woke up.

First time for everything I guess.

So Iím going to take a look at it this morning before the trip to the in laws. Been reading up on the Keihin CVK40 carb and its choke. Turns out the choke mechanism on this carb is less of a choke and more of a ďstarter enricherĒ, in that it doesnít starve the carb of air when activated, but allows more air and gas into the carb body/cylinder. Itís a plunger set-up, not a butterfly. So when the plunger is pulled (the ďchokeĒ is on) itís not choking the air but enriching the air/gas. Thatís my understanding anyway.


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Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 12, 2018, 12:29:16
Yup
It opens a little passage and allows more fuel to flow in so the mix gets richer.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 12, 2018, 15:17:38
A cold motor should always need a littke choke to start and full if very cold temp outside. If you never need the choke its way to rich and will just get worse when warm.  Maybe the choke is stuck open on the carb?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 12, 2018, 15:48:27
Pulled the whole choke assembly apart and it is possible that the cable was not fully extended, meaning the plunger may not have been fully closing in the carb.  Can't be 100% before, but I'm fairly confident now the choke is working as it should.  Off for the weekend, when I get back tomorrow I'll pull the plug and clean it, then fire up the bike again and let it idle (I'll see if starts up right away or if it needs choke), then pull the plug and see what it looks like.

Went for a ride after re-installing the choke - still blowing clouds of black smoke when I blip the throttle.  Clouds.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: SONIC. on May 12, 2018, 15:51:15
Pulled the whole choke assembly apart and it is possible that the cable was not fully extended, meaning the plunger may not have been fully closing in the carb.  Can't be 100% before, but I'm fairly confident now the choke is working as it should.  Off for the weekend, when I get back tomorrow I'll pull the plug and clean it, then fire up the bike again and let it idle (I'll see if starts up right away or if it needs choke), then pull the plug and see what it looks like.

Went for a ride after re-installing the choke - still blowing clouds of black smoke when I blip the throttle.  Clouds.

 Maybe it's just a diesel and you don't know it  ;)

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 12, 2018, 15:57:34
Maybe it's just a diesel and you don't know it  ;)
Ha!  Sure looks like one  ???
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 13, 2018, 18:13:56
I dunno man, after making sure that the choke was working properly (99% confident it is now) the plug still gets really sooty after a couple of minutes of idle only (no throttle at all). It also started up with no choke.

So the carb is dumping way the fuck too much gas into the cylinder before I even get moving. Thatís not the main jet I now know, but the pilot circuit. Iím going to pull the carb out, switch everything back to stock and see what gives.

Stock needle too? Right now I have the DynoJet needle set at stage 2. Guess Iíll switch that out as well. That way Iíll be back to baseline and can take it from there.


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Title: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 13, 2018, 18:17:30
I dunno man, after making sure that the choke was working properly (99% confident it is now) the plug still gets really sooty after a couple of minutes of idle only (no throttle at all). It also started up with no choke.

So the carb is dumping way the fuck too much gas into the cylinder before I even get moving. Thatís not the main jet I now know, but the pilot circuit. Iím going to pull the carb out, switch everything back to stock and see what gives.

Stock needle too? Right now I have the DynoJet needle set at stage 2. Guess Iíll switch that out as well. That way Iíll be back to baseline and can take it from there.


Sent from my iPhone using DO THE TON

Is the float valve working properly?
Maybe the valve isnít closing and the bowl gets overfilled?
Overflows cleared?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 13, 2018, 18:17:45
Yes, put it alk to stock abd start from there.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 14, 2018, 11:05:55
Well I'll be dipped in shit.

Said my goodbyes to the Ottawa inlaws in double-quick time, hurried the missus out the door and dropped the hammer all the way back to Montreal yesterday.  Got home, dumped the toothbrush and got straight to the garage to do what was suggested - tear the carb down and replace all the DynoJet stuff with stock. 

There was gas everywhere - in the intake and outlet rubber boots, the venturi itself was dripping, man it was seriously flooded.  Something was pouring gas into the carb no doubt, but that much was already obvious.  Checked all the specs though and I'd definitely followed the DynoJet instructions to the letter.  Still unsure as to what was causing the over-gas, but hey.  Couple of hours later I got the freshly rebuilt and cleaned carb back in the bike and took the old girl out for a spin and whaddya know.  Idles great, throttle response great, no plumes of black smoke when I blip the throttle.  Thrilled - if I had a tail I'd wag it.

So thank you for you help and perseverance guys, once again your long distance assistance has got me in the saddle rather than sitting on a shop stool staring at it.

What I noticed -

- Still need to get WOT as only took it around town, but I thought I felt a little more vibration through the footpegs
- exhaust sounded quieter (that's a good thing, just ask the neighbours)

Will get it out again today and will take it through the throttle positions and report back.  I still don't entirely understand how stock jetting/needle/idle screw etc can provide enough gas for the big bore, but as someone mentioned maybe that's balanced out by the less restrictive exhaust and modified air box?

But for now, thanks again.  You got this guy doing laps on Rhonda and now El Verdito is chomping at the bit.  Muchas gracias one and all.

Probably should get some glamour shots of the bike up soon too  8)
 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: SONIC. on May 14, 2018, 11:21:30
Huzza!!

If there was that much gas in there I'd bet that your floats were not adjustred right or sticking open. Either way congrats on getting it up and running!

If you think about the basic function of the carb:
The piston goes down and causes an air void that atmospheric pressure feels the need to fill. The air flows through the carb at high speed and runs over the jets, this vacuum effect sucks fuel up the jets into the air stream (and then into the cylinder). Stock you're getting a certain amount of air flow through that carb orifice.
When you go up in bore that "void" gets bigger so you need more air to fill it. The only way to get more air through that same carb in the same timeframe is to pull it in faster, which increases the velocity over the jets and sucks more fuel in. So on the same carb settings with a bigger bore you get more fuel than you did with the stock bore.

It's not always linear because it all depends on the design of the carb, size of the jets, etc etc but in general that's how it works.

Now that it's running close to right you can do some plug chops to see if that fixed the issue or not, you could still be rich or lean with the stock jets and you'll likely need to fiddle a bit to get it right.



Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on May 14, 2018, 11:22:48
Well I'll be dipped in shit.

Said my goodbyes to the Ottawa inlaws in double-quick time, hurried the missus out the door and dropped the hammer all the way back to Montreal yesterday.  Got home, dumped the toothbrush and got straight to the garage to do what was suggested - tear the carb down and replace all the DynoJet stuff with stock. 

There was gas everywhere - in the intake and outlet rubber boots, the venturi itself was dripping, man it was seriously flooded.  Something was pouring gas into the carb no doubt, but that much was already obvious.  Checked all the specs though and I'd definitely followed the DynoJet instructions to the letter.  Still unsure as to what was causing the over-gas, but hey.  Couple of hours later I got the freshly rebuilt and cleaned carb back in the bike and took the old girl out for a spin and whaddya know.  Idles great, throttle response great, no plumes of black smoke when I blip the throttle.  Thrilled - if I had a tail I'd wag it.

So thank you for you help and perseverance guys, once again your long distance assistance has got me in the saddle rather than sitting on a shop stool staring at it.

What I noticed -

- Still need to get WOT as only took it around town, but I thought I felt a little more vibration through the footpegs
- exhaust sounded quieter (that's a good thing, just ask the neighbours)

Will get it out again today and will take it through the throttle positions and report back.  I still don't entirely understand how stock jetting/needle/idle screw etc can provide enough gas for the big bore, but as someone mentioned maybe that's balanced out by the less restrictive exhaust and modified air box?

But for now, thanks again.  You got this guy doing laps on Rhonda and now El Verdito is chomping at the bit.  Muchas gracias one and all.

Probably should get some glamour shots of the bike up soon too  8)
You most probably have a worn/sticking float valve! At first they just stick and leak sometimes, eventually they leak all the time.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 14, 2018, 11:26:26
The vibrations may, and are most likely, a thumper thing.  Could be the balance on your rims, too, but my F650 tends to be buzzy between 20mph and 45mph.  Once I get above 45, it smooths out.  Cruising the highway at 60 mph+ it's smooth as silk, even with Karoo3 dual sport tires.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 14, 2018, 12:15:06
Right on Jimbo

Now you just need to find some fields to go tear up

(https://uploads.tapatalk-cdn.com/20180514/b0d1a9da4acef331de20da968aa7ed88.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 14, 2018, 12:36:50
Right on Jimbo

Now you just need to find some fields to go tear up

(https://uploads.tapatalk-cdn.com/20180514/b0d1a9da4acef331de20da968aa7ed88.jpg)

Ye gads, if that was my view I'd be a blur in it every chance I got!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 15, 2018, 10:44:10
Another ride yesterday and the difference is night and day.  I'm not sure if it was the pilot/idle circuit that was drowning out the carb, or the float.  I checked the float needle and it didn't appear to be sticking at all, and I'd already adjusted and measured the float height and it was spot on.  I'd love to know or figure out what was causing it, but perhaps it'll be one of those things that'll become apparent with more carb tuning experience.  I really enjoy the diagnostic/remedial process (thankfully!), and have learnt a lot already from this KLR. 

Raining cats and dogs here today.  Need to address the leaky petcock - it's not the petcock itself but rather a stripped captive nut inside the tank that the petcock bolts into.  I need to tap the bolt and that should take care of it.  It's not leaking badly, but incontinent gas tanks aren't much of a cause for celebration.

Another thing - Irk you reminded me that I need to balance the tires.  I'd already ditched the huge lead weights clamped to the spokes like tiny sloths - I used CounterAct Balancing Beads (they're like Dyno Beads) in the Honda which worked well so I'm going to use them in the KLR as well.  They're arriving today, along with some S100 cleaning stuff so Rhonda can get a long overdue brush up.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Drey6 on May 15, 2018, 11:17:49
If I were you Iíd smell my oil and inspect to see if much gas made it that far. That much flooding, Iím sure itís in there and thatís no bueno for bearings/clutches etc. Iíd change the oil/filter out as soon as you confirm your carb is dialed in correctly.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 15, 2018, 11:25:37
If I were you Iíd smell my oil and inspect to see if much gas made it that far. That much flooding, Iím sure itís in there and thatís no bueno for bearings/clutches etc. Iíd change the oil/filter out as soon as you confirm your carb is dialed in correctly.

+1 you don't want to destroy the internals now that it runs well.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 15, 2018, 11:38:15
Thanks for the suggestion guys - I'll absolutely do that.  Out of interest, how would the gas infiltrate the oil passages?  Would it be down through the rings or up through the valves?  Or both?  Or something else?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 15, 2018, 11:47:55
It's thin and if you flood your combustion chamber it will get past rings and valves and into the oil which then gets thin and stops protecting. doesn't take much to ruin the oil.  You need to change it for breaking in the piston anyway.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 15, 2018, 11:55:25
Cool, thanks Mike - when you say I need to change it for breaking in the piston what exactly do you mean?  Is this something I need to do after a certain amount of kms with a new piston/rings?  I've probably put a little over 100kms on the new piston/rings now.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 15, 2018, 12:06:15
I don't do km's, but you change the oil at 50, 500, 1500, and 5000 miles after a rebuild.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 15, 2018, 12:11:16
It's ready for an oil change in that case.  Thanks man, looks like that and the balancing beads are today's order of business.  Good to know the oil change scheduling, I didn't know that.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 15, 2018, 13:10:03
You get a lot of metal coming off the rings and bore as they seat and you want that out of the motor, it gets less and less hence the intervals getting farther apart. Also a good method to make sure they seat well, Irk mentioned is to get on and off the throttle often. So accelerate hard, close throttle and let the bike engine brake, then repeat lots of times. Change the oil. You likely will see some shiny bits in the first few changes but they should go away.  The reason for the accel, decel is it loads the rings in both directions and seats them better.  You don't need WOT, but a good fast accel and decel about the same. A quiet road or empty parking lot is good for that.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 15, 2018, 17:24:45
^^  Gotcha, I'll do that.  Pretty sure I know the answer to this already - but each time I do one of these oil changes I need a new filter too, right? 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 15, 2018, 17:53:58
Prob a good idea on at least the first couple, some folks cut them open to see whats been trapped.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 15, 2018, 18:52:10
Depends on the oil filter.  Some, like the K&N can be cleaned and re-used.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 15, 2018, 19:35:34
Just drained the oil and will switch out the filter after my tea - it's a Hi Flo Filtro filter.  Picked up a couple from Kawasaki for a few bucks.  The oil looked pretty clean when it drained, didn't see any shiny stuff in there but I'll have a closer look later.  Didn't smell too gassy either - would there be a sure sign that there was gas in the oil?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 15, 2018, 20:42:56
You would smell it if it was there.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 16, 2018, 10:35:02
I thought so Irk - it may have smelled a little funky but that might just have been because the oil was really warm or that it's Rotella and I'm not used to it.

Hopefully getting my tank sorted today, and getting those balancing beads in the tires.  KLR's getting close now - once a few details are taken care of and the carb is dialled in then it's off to the races.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 16, 2018, 11:32:51
Filled up with more of the Rotella and a new filter, and did what was suggested - took the bike up and down Mount Royal a bunch of times.  Not only a barrel of fun, but I used engine compression to brake and did a bunch of accel/decel to get those rings seated.  Love riding this bike around the city at night - it has an unruly, reprobate character that appeals no end.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 16, 2018, 11:55:11
Nice.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on May 16, 2018, 13:25:36
Using engine compression to slow down is fun on singles, I think you are going to have a lot of fun on this bike.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 16, 2018, 14:11:44
It's balls-out brilliant is what it is.  And it hasn't even gone off-road yet either.  The C model I now know was built with more of an off-road approach so I'm really looking forward to getting off the asphalt.  Worth noting that while my off-road skills aren't at zero, they hardly bother the double digits either.  Thrashing old Suzukis and Kawasaki's around Bali years ago and a bike trip across Nicaragua is pretty much the sum total of dirt.  Oh, and my first bike of course, a 50cc dirt bike that I had as an 11 year old. 

Actually, that was the first bike I ever customized, when I rode it full tilt into a ditch.  It never looked quite the same after that.  Not sure I did either.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 16, 2018, 15:18:48
when I rode it full tilt into a ditch.  It never looked quite the same after that.  Not sure I did either.

Itís all starting to make sense now.
So now youíre due for an 800km ride before the next oil change, go find some dirt roads to thrash!
Gotta be some just north of mtl i would think?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 17, 2018, 16:39:35
Itís all starting to make sense now.
So now youíre due for an 800km ride before the next oil change, go find some dirt roads to thrash!
Gotta be some just north of mtl i would think?
Have to be.  A mate here has a DR650 and loves to belt the thing out in the bush - once I get everything squared away then I'm hoping to get loco out in the sticks.  Work's getting in the way of the fun stuff (surprise surprise) but hoping to get the petcock nuts inside the tank tapped tomorrow to stop the leak, and also a bit more carb work done over the weekend.

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 18, 2018, 14:40:59
Got the stripped nuts in the tank tapped - anyone know if teflon washers will work for using with the petcock bolts instead of nylon?  Couldn't find the latter in Canadian Tire so grabbed what I could in the plumbing dept.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 18, 2018, 15:27:32
Teflon deteriorates with fuel.  Copper crush washers should work.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 18, 2018, 15:30:44
Are nylon washers also a no-no?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 18, 2018, 15:32:33
Nylon is fuel resistant.  Lots of fuel line is made from nylon.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 18, 2018, 15:48:50
Cool thanks man, I'll pick some nylon ones up tomorrow
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 18, 2018, 16:40:31
Probably very obvious and already done, but make sure you flush that shit out thoroughly.
No need to find out how easily those freshly cleaned carb jets can get plugged.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 18, 2018, 16:49:30
I'll be rinsing it out the best I can with some gas, yeah.  Those metal shavings are gonna be pretty small - any left in the tank hopefully will get caught by the petcock filter or the fuel line filter I installed.  Hopefully.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 20, 2018, 11:04:40
Guys, question - think the standard recommended spark plug for this bike (NGK DPR8EA-9, or NGK DPR8E1x-9 Iridium) will do the job now that it has an over-bore?  Or do I need something with more bang?

The starter switch had been playing up so that got taken apart yesterday - turns out there was a bunch of gunk in there that was messing up the contacts.  Three tiny springs and one tiny ball bearing - so many opportunities for a major fail.  Did break a small plastic shoulder on the switch innards, but some well-aimed super glue and the thing was back in business.

Also tidied up the bars and controls - the throttle cable housing now sits prettier as do the brake and clutch levers.  Think I may have flooded the carb with all the throttle opening and closing while I was adjusting the cables - bike started right up and lo and behold there were the huge plumes of black smoke from the exhaust along with some backfires this time.  Really hope things even out next time I fire it up - I'll let it idle and not crack the throttle.

Also picked up Rhonda's new seat last week, but that's for a different thread...
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 20, 2018, 11:13:05
Guys, question - think the standard recommended spark plug for this bike (NGK DPR8EA-9, or NGK DPR8E1x-9 Iridium) will do the job now that it has an over-bore?  Or do I need something with more bang?

The starter switch had been playing up so that got taken apart yesterday - turns out there was a bunch of gunk in there that was messing up the contacts.  Three tiny springs and one tiny ball bearing - so many opportunities for a major fail.  Did break a small plastic shoulder on the switch innards, but some well-aimed super glue and the thing was back in business.

Also tidied up the bars and controls - the throttle cable housing now sits prettier as do the brake and clutch levers.  Think I may have flooded the carb with all the throttle opening and closing while I was adjusting the cables - bike started right up and lo and behold there were the huge plumes of black smoke from the exhaust along with some backfires this time.  Really hope things even out next time I fire it up - I'll let it idle and not crack the throttle.

Also picked up Rhonda's new seat last week, but that's for a different thread...

Plugs only vary by heat range
They do this by varying the length of the tip ďnoseĒ for lack of a better word.
This affects how much thermal energy is absorbed by the plug.
Because the rate the plug transfers thermal energy to the head is constant, this changes the temperature of the plug.

You want your plug to be operating at the optimal self cleaning temperature range.
To hot and you melt it and probably get lots of detonation.
Too cold and the plug fouls more often.

The only way to get more ďbangĒ is if you get more voltage from the coil.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 20, 2018, 11:18:32
Great info mate, cheers fella, makes sense.  Is there a way to find out if the plug is operating at peak temperature?  I'm going to switch out the plug for a new one anyway, but I wonder if maybe the old one is operating too cold and therefore is fouling more often?  Could it be that the plug was just old and therefore not doing its job properly?

The petcock fix has held so far - I found some nylon washers and the newly-tapped nuts in the tank are holding.  So far, so good.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 20, 2018, 11:51:12
Great info mate, cheers fella, makes sense.  Is there a way to find out if the plug is operating at peak temperature?  I'm going to switch out the plug for a new one anyway, but I wonder if maybe the old one is operating too cold and therefore is fouling more often?  Could it be that the plug was just old and therefore not doing its job properly?

The petcock fix has held so far - I found some nylon washers and the newly-tapped nuts in the tank are holding.  So far, so good.

Once they start to foul, you can never really clean them. You can make them work but they will foul a lot easier. best bet is to change it and go for a lengthy ride.
Should be a nice tan brown colour when you check it.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 20, 2018, 12:09:30
No local Napa has the Iridium plug in stock but do have the regular one - think it'll do the job?  Would the iridium plug provide a significant performance improvement?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 20, 2018, 12:16:34
From what ive read iridium is more for lasting longer than performance. You get 20k out of standard and 80-100k out of iridium, unless you foul it etc then you just wasted $$
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 20, 2018, 12:26:27
Think Iíll just pick up a few regulars then. Until I know Iím not gonna keep fouling the things anyway


Sent from my iPhone using DO THE TON
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 20, 2018, 12:26:55
Thats what I'd do too.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on May 20, 2018, 12:48:08
You can also look if they have a P type also, the nose protrudes a bit and so they run a touch hotter, but not a full heat range, kinda like halfway between.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 21, 2018, 11:37:50
Picked up a few NGK spark plugs yesterday from the local Napa, and while I'm blethering away with the guy there I see this torch (aka "flashlight") on the counter -

(https://i.imgur.com/3qCu5pi.jpg?1)

I always take the piss out of my wife for being a "point-of-sale girl", meaning she has a hard time walking through the aisle at the checkout without grabbing some useless shit for $15.  But there I was, torch in hand, thinking I gotta make this mine.  No ordinary torch you see, behold! -

(https://i.imgur.com/NIzYcyW.jpg)

- pull down the bulb part a smidge and a little stem pops out - give that thing a pull and wonder-of-wonders a 2ft telescopic magnet with a flexible head is revealed in all its telescopic magnetic glory.  "That sucker's coming home with me", I thought to myself, "ironic point-of-sale purchase be damned".  And it did.

In less important news, got a new plug installed and went for a ride.  Definitely feels crisper, no doubt.  But still need to do these "plug chops" which is a new one for me.  Today's a holiday here, my wife is threatening to drag me up a mountain for some "fresh air" but if that plan goes south then I know what I'm doing.

 

 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 22, 2018, 10:51:50
Nice, those things come in very handy sometimes. I got to do one last ride on the CX yesterday, delivered it to the new owner, new rider. Was an hour ride along the river, a little sad to see her go, she's running perfect but needed the $$ and have the GL.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 22, 2018, 11:03:32
Happy for you mate - it's always a little bittersweet selling a bike but sounds like your CX went to a good home.  Glad you got a decent ride in to see her off.  I got Rhonda's new seat installed and wheeled her out ready for her inaugural ride - as soon as I turned the gas on at the petcock it pissed all over the starter motor.  Leaky inline fuel filter, one of those fancy glass ones.  So much for that - have 6 cheapo ones from FortNine on their way for $10 (Bikemaster), hopefully they'll be here tomorrow and I can take the old girl out for a waltz.

The KLR is running pretty good, but still need to do the plug chops.  I'll be going back in this thread to read again what the procedure is and hopefully get it down in the next day or so.  Also wondering about the bars I chose.  Picked up some Moose bars from a local guy here - they look great and are thick-walled aluminium so they perform great too.  But they're a little narrow, and I'm not sure they're high enough either.  I tricked out the grips to give me a few extra inches of width, but thinking I may need risers or different bars entirely to make long distance riding more comfy. 

For example, every time I apply the front brake (the back brake not so much) I get a lot of pressure on my left hand.  Think it must be because of the bar position - if they were a little higher (and certainly wider) it would make for a more comfy riding position.  Any suggestions for some decent bars?  I still have a $100 gift certificate from the guys at Dime City so maybe could splurge on a new set.

Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 22, 2018, 11:07:33
Bars are hard to do, I generally try and find a set that measures in the areas I want different, most have height, width and pull back measurements and if you know the current, look for a set that adds to the dimension you want different.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 25, 2018, 12:11:57
Still waiting on a few bits and bobs but El Verdito is pretty much a wrap.  It's running great with the stock jets all the way through the throttle positions, but think there's some room for improvement.  Got some shots yesterday -
 
(https://i.imgur.com/nanhPJQ.jpg)
(https://i.imgur.com/xBX9NpA.jpg?1)
(https://i.imgur.com/jaXBIm8.jpg)
(https://i.imgur.com/NitBPo1.jpg)
(https://i.imgur.com/0rs1xys.jpg)

Summer's looming large, time to have at it  8)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on May 25, 2018, 13:04:10
Nice, looks great, now to get her dirty.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on May 25, 2018, 14:03:25
Nice!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on May 25, 2018, 14:19:06
Man, the KLR is the tits.  The green and steel combo works perfectly together.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on May 25, 2018, 14:52:02
Man, the KLR is the tits.  The green and steel combo works perfectly together.

+1
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 25, 2018, 15:42:55
Thanks gents, and thanks again for all the help making it happen.  And as much for my shite memory's sake as anything else, here's a list of everything that was done -

- bike stripped, frame powder coated - new swingarm bearings
- forks seals replaced
- front and rear brake callipers rebuilt, rear brake master cylinder rebuilt
- valve shims checked and replaced where necessary, new gaskets and seals throughout engine and oil galleries 
- "doohickey" (idler shaft lever on the counterbalance chain) replaced with Eagle Mike lever and torsion spring
- oil pump rebuilt
- engine bored to 685, stock piston replaced with Wossner piston and rings, steel 3 ply head gasket
- cooling system cleaned and rebuilt
- carb cleaned, new vacuum slide (from HD), rebuilt with DynoJet needle and jet - then rebuilt again back to stock...somewhat a work in progress
- Lexx muffler and midpipe - header sandblasted and repainted
- modified airbox, snorkel removed
- upgraded rear subframe bolts
- new choke assembly and cable, new clutch cable
- restored fairings and headlight cowl
- inside tank de-crapped, rust removed, tank paint stripped, steel brushed and 2K gloss cleared
- new petcock, fuel lines, fuel filter
- KLX front fender and fork boots
- handmade KLR badges and other stainless steel snazzy panels
- painted side panels
- Shinko 705 tires
- Moose Racing aluminium bars, Renthal grips, Ken Sean folding mirrors
- new battery, all fluids replaced, new fuses
- side stand safety switch disabled

... might be some more things, I'll add to this list when the old grey matter kicks in again after lunch.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: canyoncarver on May 25, 2018, 16:07:03
Best looking KLR I've seen yet.  Great job man.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 25, 2018, 17:44:53
Mighty kind of you my man, thank you.  Looking like a weekend of rain so might squeak out from behind the desk and take her out for a stretch.

Fired up the CB as well yesterday - almost forgot how much I love that bike.  Got a chronic RSI in my elbow from the clutch last year - managed to re-route the cable and play around with various levers on the bars and really freed it up.  Much better. 

Now need to work on my stunt bike skills so I can ride them both at once.   
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 28, 2018, 22:30:30
Some days it's the small things...

(https://i.imgur.com/iqsCppT.jpg)

(https://i.imgur.com/tmyLZzu.jpg)

(https://i.imgur.com/WwHd3Yc.jpg)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on May 30, 2018, 23:07:57
Right on - BOTM nomination.  Alright!  This feeling will never get old...

Here are a couple of close-ups.  Apart from the mechanical work and modifications, I think of all the aesthetic work I did on the bike it's the combination of the restored lime green fairings with the brushed steel that float my boat the most.  If green's your thing, you can never have enough of it.

(https://i.imgur.com/umC7ZZP.jpg)

(https://i.imgur.com/8ASgFuO.jpg)

(https://i.imgur.com/BNOR0V1.jpg)

Mechanics-wise, the big bore and lighter piston not only piles on the torque but also smoothes out the vibrations that these thumpers are known for.  The Lexx exhaust by the way (apart from shedding a few pounds from stock), sounds bloody fantastic.  Riding the thing's an absolute riot.  But yeah - this thing needs to see some dirt.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on May 30, 2018, 23:17:23
Well done mate. This thing looks tits.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Jun 01, 2018, 03:34:16
Absolutely fantastic
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jun 02, 2018, 00:38:32
Cheers guys, really appreciate that

And here I am, standing on the shoulders of giants once more


Sent from my iPhone using DO THE TON
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: 3DogNate on Jun 05, 2018, 17:02:37
Just finished reading your build... Kudos!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jun 05, 2018, 17:16:59
Cheers man, appreciate it

Learnt a ton during this build - still need to work on the carb a bit but man this thing's got some go.  I don't know much about power bands and all that but now it has a bigger cylinder it really changes the way the thing moves, especially at speed.  Had it on some quiet highway the other day, got her up to 115, 120 - grabbed a handful of throttle and the thing erupted.  Just got masses of torque and velocity that I wasn't expecting.  Hoping for, but not expecting. 

Granted, the brakes are a little squishy, but think that's probably got a lot to do with the decades old brake lines.  Teeing up some braided lines as we speak.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jun 10, 2018, 20:13:59
Ok, shit - I f*cking love this thing.  300kms today - 160kmph no drama on the highway and finally found some dirt.  Didn't get shot at by a farmer but think it could've gone either way. 

(https://i.imgur.com/uFw6Ns1.jpg)
(https://i.imgur.com/NJKF4aU.jpg)
(https://i.imgur.com/V75V3a5.jpg)
(https://i.imgur.com/uQXoaGK.jpg) 

Fairly confident that my clutch cable is on its last legs but holding off buying a new one until I decide on the bars.  The Moose bars I bought are both too low and too narrow - I've found some ATV bars that are a close match to stock.  The clutch is a little stiff - hoping when I spring for the new bars not only will the ride be more comfortable but the extra few inches will soften up the clutch cable too.

This bike is the nuts.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jun 10, 2018, 20:50:52
Those purple flowers in the second shot?  No fluke.  Thought about riding right through them too but, well, you know.  Nature.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Jun 10, 2018, 22:20:40
Awesome.  Waiting for the river crossing...
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Jun 11, 2018, 01:58:00
Looking good Jim. Looks like you found the right roads, too.


Sent from my iPhone using DO THE TON
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jun 20, 2018, 14:19:22
Got the bundle clamp/p clamp/d clamp/cable clamp dammit and installed the tool tube I picked up on kijiji for a song -

(https://i.imgur.com/3t7CA5Q.jpg)

(https://i.imgur.com/53WsB9K.jpg)

The clamp secures the lower part of the tube and the upper part bolts on to the frame with a bit of finagling.  These tubes are great, waterproof and tough as nails.  I dumped the bike in the middle of a lettuce field over the weekend and absolutely no harm done - in fact the mud and shit looks way better on the KLR than it did in that guy's field.  Skinned my knee - I consider both me and the bike now blooded. 

Need to knock up some kind of tool roll and then I'll totally look the part.  Even have a set of tire irons that I have absolutely no idea how to use.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Jun 20, 2018, 15:42:51
Looks good, and I lost my good set of tire irons someplace between North Conway and home. There was a hole in my saddle bag I had patched, only the patch let go and they fell out. Pissed cause now I need to buy new ones.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Jun 20, 2018, 15:57:55
Bummer.  I picked mine up from FortNine -

https://fortnine.ca/en/bikemaster-8in-tire-irons-04-008

Always a good bet, and free shipping if your order comes to $50. Now I just need to learn how to use the things.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Jun 20, 2018, 16:10:27
I had 2 of these and they are the best shaped ones I've used:

https://fortnine.ca/en/motion-pro-16-inch-curved-tire-iron

I have 2 others that are not as good.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: doc_rot on Jun 22, 2018, 02:26:15
I had 2 of these and they are the best shaped ones I've used:

https://fortnine.ca/en/motion-pro-16-inch-curved-tire-iron

I have 2 others that are not as good.

+1 for the motion pro. the extra leverage of a 16" makes changing a tire a breeze. I usually use 3 irons. two for prying, and a small 8" to hold the bead while i reposition one.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Jun 22, 2018, 08:27:26
+1 for the motion pro. the extra leverage of a 16" makes changing a tire a breeze. I usually use 3 irons. two for prying, and a small 8" to hold the bead while i reposition one.

That's my exact method. I still have the smaller one, that was in my tool roll
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 06, 2018, 15:50:43
In a case of once seen can't unsee, decided the huge black hanging down rear fender had to go.  Made some brackets to hold the indicators along with a large aluminium plate that runs underneath the rear green fairing to keep the wiring and everything else under there nice and protected.  Relocated the license plate and tucked up all the wiring...

(https://i.imgur.com/Q2m6Kfi.jpg)

(https://i.imgur.com/fvbvda6.jpg)

Definite improvement I think.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Aug 06, 2018, 16:35:44
I like it!
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Aug 06, 2018, 20:24:24
Much improved
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 13, 2018, 13:11:56
My dear old Mum calls me up and says she wants to get me something nice for my birthday - is there anything I really need?  Quick trip up the highway 20 later and the KLR is now kitted out with these -

(https://i.imgur.com/ZbZzCGe.jpg)
(https://i.imgur.com/uW6o6Sg.jpg)

Pro Taper ATV high bend, the difference is night and day.  I can't put risers on as one of the bar clamp threads is a bit skewed (there's a TimeSert in there but the angle isn't perfect) and so I wanted a taller (and wider) set of bars.  These are perfect and the difference they make to the bike and the ride is remarkable.  So much more comfortable and ergonomic, not to mention some new Biltwell kung-fu grips (oxblood, FTW) which definitely don't hurt either.

Cheers Mum  ;D

While I was at it I figured it was a good time to try and sort out the intermittent starter button issue I had.  Sometimes the button fires the bike right up, sometimes I have to whale away at the button/bars until I get a good connection.  Not a cool-looking getaway by any means.  Dismantled the starter button assembly, gave the contacts a sand and cleaned everything up (again) but still no dice.  Figured it had to be something else but as i'd already deleted the kick stand cut-off switch I was running out of ideas.  After much head-scratching I discovered it was the small switch in the clutch lever - there's another contact switch in there and I found that I'd forgotten to install the tiny spring under one of the contacts, meaning it only sometimes had good contact with the switch.  Miraculously I'd found a tiny spring in the garage months ago and held onto it thinking it looked like it came out of something significant - now it's back where it should be the bikes fires up first time every time. 

Oh, my my, oh, hell yes, honey put on that party dress.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Maritime on Aug 13, 2018, 14:15:59
Nice Jim, and I never throw little springs away, they come from someplace and should go back.  I had one of them come out of the starter bit of the GL flywheel. found it just before putting the whole motor back in, it would have been very bad for that spring to be missing.  Many hours of work to pull the engine back out to replace it and the starter would have bound up the first fire without it.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 13, 2018, 14:19:56
I'm adopting a never-throw-anything-away approach in my garage now.  It's amazing how often something that could so easily have been thrown away comes in so useful.

Said every hoarder everywhere. 
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: farmer92 on Aug 13, 2018, 14:52:53
I'm adopting a never-throw-anything-away approach in my garage now.  It's amazing how often something that could so easily have been thrown away comes in so useful.

Said every hoarder everywhere. 

Ainít that the truth ruth?
Thank you for helping me justify the pile of stuff building up in the corner of my shed
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Aug 13, 2018, 15:52:06
I'm adopting a never-throw-anything-away approach in my garage now.  It's amazing how often something that could so easily have been thrown away comes in so useful.

Said every hoarder everywhere. 
The CB360 I sold this summer, the one I made a sort of 378cc desert sled out of, I built almost completely from parts I had accumulated over the last 5 years.  I may have put in $600 total into that bike, and that includes the bore, head machining and all the consumable parts like copper head gasket, seals, etc.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: Hurco550 on Aug 13, 2018, 15:55:30
The CB360 I sold this summer, the one I made a sort of 378cc desert sled out of, I built almost completely from parts I had accumulated over the last 5 years.  I may have put in $600 total into that bike, and that includes the bore, head machining and all the consumable parts like copper head gasket, seals, etc.

that compounds the reason I got rid of the ironhead, none of my pile of jap crap parts (less the showa front end) worked on the Harley, and I had no desire to start collecting junk parts for another brand of motorcycle.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Aug 13, 2018, 15:59:43
that compounds the reason I got rid of the ironhead.
Yep.  I enjoyed building that guys Sportster, but it was really annoying having to buy all new hardware, since everything is SAE.  It really does keep me away from HD, too.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: CrabsAndCylinders on Aug 13, 2018, 23:52:22
I'm adopting a never-throw-anything-away approach in my garage now.  It's amazing how often something that could so easily have been thrown away comes in so useful.

Said every hoarder everywhere. 

The tough part is organizing the "stuff" to the point where you can find the stuff you want.  I need to revamp but I will be moving it all next year.  As long as I have music playing it's always a good time in the garage.  Now where is that box of connectors?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 14, 2018, 02:14:04
I swear I spend more time looking for shit in my garage than I do using it.  Absolutely sends me.  Like, loony tunes. 

Still, holding onto stuff is where it's at.  The brackets I made for the rear indicators were salvaged from some shelving material I didn't throw away thinking I may need it one wet Wednesday.

And yes to having to buy stuff for HD's.  Well, no.  Had to shell out a bunch of dollars on tools and fittings for the Sportster once I released it was all built different.  The 1" spanner (what we call a wrench where I come from) has come in useful on several axle bolts though so not a total bust. 
Title: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 14, 2018, 19:19:21
Pretty sure the bike is still running a bit rich. It idles ok (a little high maybe) but more telling is the smell of the exhaust. No huge clouds of black smoke by any means, but a definite gassy smell.

Am I right in thinking the culprit could be the pilot jet or pilot screw? I need to pull the spark plug and have a look at that thing. But it really seems that itís only in low rpms and idle that itís rich.


Sent from my iPhone using DO THE TON
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: canyoncarver on Aug 15, 2018, 13:19:48
Yep.  I enjoyed building that guys Sportster, but it was really annoying having to buy all new hardware, since everything is SAE.  It really does keep me away from HD, too.

Isn't your Chevy all SAE?    LOL
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: irk miller on Aug 15, 2018, 14:30:06
Isn't your Chevy all SAE?    LOL

Busted.  :( HAHA
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Aug 16, 2018, 08:47:25
My dear old Mum calls me up and says she wants to get me something nice for my birthday - is there anything I really need?  Quick trip up the highway 20 later and the KLR is now kitted out with these -

(https://i.imgur.com/ZbZzCGe.jpg)
(https://i.imgur.com/uW6o6Sg.jpg)

Pro Taper ATV high bend, the difference is night and day.  I can't put risers on as one of the bar clamp threads is a bit skewed (there's a TimeSert in there but the angle isn't perfect) and so I wanted a taller (and wider) set of bars.  These are perfect and the difference they make to the bike and the ride is remarkable.  So much more comfortable and ergonomic, not to mention some new Biltwell kung-fu grips (oxblood, FTW) which definitely don't hurt either.

Cheers Mum  ;D

While I was at it I figured it was a good time to try and sort out the intermittent starter button issue I had.  Sometimes the button fires the bike right up, sometimes I have to whale away at the button/bars until I get a good connection.  Not a cool-looking getaway by any means.  Dismantled the starter button assembly, gave the contacts a sand and cleaned everything up (again) but still no dice.  Figured it had to be something else but as i'd already deleted the kick stand cut-off switch I was running out of ideas.  After much head-scratching I discovered it was the small switch in the clutch lever - there's another contact switch in there and I found that I'd forgotten to install the tiny spring under one of the contacts, meaning it only sometimes had good contact with the switch.  Miraculously I'd found a tiny spring in the garage months ago and held onto it thinking it looked like it came out of something significant - now it's back where it should be the bikes fires up first time every time. 

Oh, my my, oh, hell yes, honey put on that party dress.
Those damn kung fu grips lasted max six months for me..
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 16, 2018, 10:24:49
Quote
Those damn kung fu grips lasted max six months for me..
But what a six months!  8)
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 16, 2018, 10:32:37
Anyone have any suggestions about the rich idle?  Might it be as simple a fix as dialling down the pilot screw?
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: advCo on Aug 16, 2018, 10:36:27
Anyone have any suggestions about the rich idle?  Might it be as simple a fix as dialling down the pilot screw?

Play with the idle screw when the engines nice and warm. Try some plug chops at 1/4 throttle and you may need to go down a size or two on the pilot. But I'm no expert.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: The Jimbonaut on Aug 16, 2018, 12:01:28
I'll do that mate - I have the screw at three turns out at the moment I think - that's the suggested DynoJet setting.  Although I've pulled all the DynoJet stuff out of the carb and switched everything back to stock, the screw may still be at the suggested DynoJet position.  I'll dial it down and see what gives.
Title: Re: KLR You Experienced? Err, kinda not really.
Post by: datadavid on Aug 16, 2018, 13:58:17
But what a six months!  8)
Yea they were really nice to begin with! Think i rode around too much with greasy hands(triumph chop) so if you keep them clean they might last better, i ended up with rubber peeling off in rings..