Assembling a Hack

Took it step further and removed the next case and flywheel. This is what I found.

Luckily both pieces were still attached and not wandering around loose. Installed an upgrade, an Eagle Mike cam chain tensioner with torsion spring.

Look at that broken spring - sure glad you took the time to inspect before the journey. Looks like you're making good progress.

By the way, I've "heard" that a smaller front wheel, say 18", will reduce trail on a KLR with favorable results.

Uhhh, that was close. Thank you for reminding me.
So in the future each time I take that slack out, I will have to recheck if it does it in deed!
In fact twice I have heard a small movement...tick.
Continue well in your preparations.

Sven

Peter Pan - 2/9/2015 7:44 AM

So in the future each time I take that slack out, I will have to recheck if it does it in deed!
In fact twice I have heard a small movement...tick.
Sven

Sven if you remove the left side case cover, you should be able to see the spring behind the doohickey. To test if the spring is working, loosed the bolt holding the cam chain tensioner one half turn. With a long screwdriver, push the Doo to the right, then release. If working properly, it will return to center on its own. If not, then something is wrong and you will have to remove the second case and flywheel to see why the Doo doesn't return to center.

Ride safe
Jan

Sorry for the delay in build progress. Life keeps interrupting.

Every morning I kept finding a small dribble of oil on the lift. Discovered the rear shock is shot, leaking oil. Looked into rebuilding the OEM shock, was told is not feasible, and if feasible, not cost effective. Then looked at the cost of an aftermarket shock.... WOW! Since DMC is going to install a stronger spring on the rear shock as part of the package purchase, opted for buying another OEM shock off eBay.

The KLR has been recolored and slowly coming back together.

As boxes of bits and pieces arrive, they are added on.

As she stands now, the bike is ready to ride. But, Sorry Charlie, she will NOT be getting fitted with a sidecar....!

A big eyed beauty has entered the picture and will be the new tug of choice.

nice colours nice eyes. I have seen that face somewhen in a film. ( together with Gregory Peck?)
The brown one is service friendly...what fore to wash?
Thank You for the tip and explanation.
Sven

Finished up the Gen 1 KLR, thought it was sold, but still have it. Is getting crowded in the garage with three bikes here. Need to make room for the crate coming from DMC.

Have been working on the Gen 2 KLR, while we wait for the sidecar chassis to arrive. Added handlebar risers, USB port on the front, LED headlight bulbs, fork brace, installed the upgraded Doohickey, the saddlebag rack and topbox plate.

The bike's wiring was studied and changed around. Getting under the seat to check a fuse takes too long when on the side of the road. So the main fuses were relocated to under the left side panel. Since I'll be wiring in additional outlets, looked and looked for a fuse block that would fit the KLR, finally found a long narrow one for six fused circuits. Again mounted it on the left side so I can check and change any fuse without having to remove multiple nuts and bolts.

Decided to upgrade the drive chain and sprockets for pulling a sidecar. Installed a heavy duty 525 o-ring chain, a 15 tooth 525 counter sprocket and and a 49 tooth rear sprocket.

Little by little the big eyed beauty is getting ready for a rolling chassis. DMC Sidecar advised me to be on the look out a a large wooden crate arriving soon. Christmas in April, I love it.

Other work done was to upgrade the rear subframe with the Eagle Mike kit by drilling through the main frame backbone. Installed a simple non-vacuum petcock on the gas tank, then rejected the carb. Not sure if will change the exhaust or not. The DG is too loud, but would like a more open flow, without spending a lot.

Hey, that's a good idea moving the fuse block for easy access.

Yesterday was a good day. Was able to complete several items that were waiting for parts to arrive.

Removed the front wheel, dropped the forks in order to reposition the handlebar cables from in front to behind the triple tree. With the handlebar riser they were tight and binding in front.

With the front wheel off, replaced the stock brake rotor with a larger 320mm rotor for better stopping ability. While on the front, replaced the stock rubber brake line with a Galfer steel braided line, then proceeded to replace the brake fluid and bleed the air out. Installed the spacer from Eagle Mike to relocate the brake pistons to accommodate the larger rotor. With the front end reassembled, turned to the rear brakes

Left the rear stock rotor as is, but upgraded to a Galfer steel braided line. More important, added a double banjo bolt and the brake line for the sidecar. The sidecar brake line has a quick disconnect coupling for when you need to disconnect the sidecar from the bike for any reason. The electrical connections will also have an in-line plug for uncoupling. Don't plan on riding this bike without the sidecar, but if the bike later needs to go up on a lift for service, is best if the sidecar can be easily uncoupled.

Final task on the rear brakes was to replaced the brake fluid and bleed the air out. Of all the wrenching tasks on a bike, to me, working on brakes and bleeding them is the least desirable chore of all. But is now done and can focus on more enjoyable wrenching.

Trucking company called, they have a crate for me. Oh boy, Santa's coming.

Now it looks as if things become more interesting 🙂

Santa arrived.... the crate was delivered. Popped off the end panel to reveal the DMC 19" wheel. Quickly the top and siders were removed. There she was, the DMC rolling chassis ordered back in early February. Quickly parts were unwrapped and organized for installation.

First there undercarriage, that went pretty smooth. Then the upper two brackets. Wasn't sure if the engine bracket would fit, seeing as how you have to thread it in and around the various parts but everything came together and was tightened.

Progress was made installing then undercarriage and both upper mounts. The undercarriage, that went pretty smooth. a little friendly persuasion at times, but smooth. The upper two brackets took some study and thought. Wasn't sure if the upper front bracket would fit, seeing as how you have to thread the pieces in and around in order to bolt together using six bolts. Once installed it is very secure, rock solid. With everything in place, all bolts were tightened.

Wiring for the sidecar and driving lights were completed and ready to go. Finally body panels were reinstalled.

Would love to get the bike off the lift and attach the sidecar next week, but tax return preparation time is now!

Those Harbor Freight lifts are somewhat spooky. I replaced my neighbor's safety stop (conduit) tube with a 3/4" solid cold rolled steel bar. It bent easily with a middleweight bike on the hoist.
That take out piece under the rear tire is also easily displaced.

Be careful with it!

Lonnie