he also had the sidecar mounts fail(again). He got them welded up in Troutlake, but a more permanent solution was needed
he came up this weekend to effect some repairs. We rolled the bikes out of the garage to make room
Andy took some measurements to establish where he started, before removing the damaged swingarm
the new unit is a little different so Andy had to drill new mounting holes and place it a little forward
the red paint outlines the old torsion axle position
DMC provided the new torsion axle and hardware to fabricate better sidecar mounts. Andy set the sidecar up level and on his marks to determine where the new bottom mounts should go.
There was a good deal of prep work before we could weld up the new mounts. Andy cut some tabs and brackets
Shaping the new brackets on the bench grinder
and using an angle grinder to clean up and ready the chassis for welding
Lining the new mounting hardware up with the subframe
Jay provided some brackets which we welded to the clamps and then to the bottom of the sidecar chassis
Before we turned the sidecar back over Andy cleaned the welding spatter out of the clamps
and spray painted the raw welds
The fussy work continued: Andy set the sidecar up level and on the marks again and strapped down the rear suspension of the bike and bolted up the bottom mounts. Now he was ready to determine the new position for the strut mounts...
The welds are ugly, but I think I got good penetratrion and they did not deform or break when I beat on them
Andy was able to ride the bike home last night. We still have a little more to do before we can mount the body back on the chassis
Hello Vernon,
how comfortable are you with the KLR650 as rig in rough high mountain range?
I have the fear that I would damage frame and engine very fast....
My Jawa the 350 2 stroker had 3 engine total damage in 29000km less then 20.000mi
And I fear the KLR would do only some 20.000miles and become totally worn out as rig.
Beside I don't find it would have enough space for a beefy subframe.
What is your opinion?
Sven
Sven
I am not sure how you could make those predictions with any accuracy. The KLR is not the best bike manufactured, but it should certainly hold up better than a Jawa 2 stroke of half the displacement. The frames are difficult to fit a good subframe to, but it can be done. We did break three bike frames because of inadequate subframes and very hard usage. One had an early DMC subframe with the top front mount attached to the downtube near the exhaust port, two were equipped with a subframe of my design with the top mount carried on the one piece subframe just above the top front motor mounts. All broke just above the top strut attachment to the bike. DMC has redesigned the top front mount and it attaches to a much stronger part of the bike frame.
Currently we are using the newer DMC top front mount and the other three mounts are carried on a home built subframe. I also have a DMC complete subframe on 2 rigs. One of these I modified by tying an arm from the top rear clamp to the main subframe just behind the right foot peg. This makes the subframe carrying the bottom mounts and the top rear strut mount one piece, re-enforces the rear frame loop of the bike and prevents that clamp from slipping or rotating. I think this is the best arrangement, but we have not had any frame breakage with any of the current set ups and they have all been used in class and in rallies.
The KLR motor is robust and well tested. Keep the coolant and oil levels up and the valves and chains adjusted and it should last a good long while, sidecar or not. The CV carbs should self adjust for altitude. I gear mine down for hauling a sidecar and beef up the suspension a little.
In my opinion KLR build quality is not all that great and the design is outdated, but for the price it is a solid, capable motorcycle and makes a decent sidecar rig for moderate speed and back country use. There is a ton of after market and used parts available at low prices, allowing you to effect repairs and custom tailor the machine to your needs. Check the KLR forums for specific information about the strengths and weaknesses of this bike.
Peter Pan - 7/18/2012 10:52 AM
Hello Vernon,
how comfortable are you with the KLR650 as rig in rough high mountain range?
I have the fear that I would damage frame and engine very fast....
My Jawa the 350 2 stroker had 3 engine total damage in 29000km less then 20.000mi
And I fear the KLR would do only some 20.000miles and become totally worn out as rig.
Beside I don't find it would have enough space for a beefy subframe.
What is your opinion?
Sven
Vermon,
The estimates come from something more then 200.000.miles on 7 different bikes (incl 2 small 2 stroker rigs 36.000mi) in 20 (30) years riding plus 22 years machine shop hand on experience, but none with KLR rigs as you have.
thank you for your insight description , 3 broken frames sound bad on one side, but on the other side your improvements make me hope for to convert the KLR into a rig is still an option..
The mind is working...
Well, for now I better do my work, some money has to enter the door.
I might call you in a week or so for to analyze what is the best way to go.
Thank you very much
Sven
Andy brought some more MIG wire up yesterday
after fussing with the welder a bit we were able to finish welding up his mounts. We tipped the rig on it's side so I could get at the bottom side of the new tabs
With the welds completed, Andy was able to fit the body and bolt it down.
He took it home to paint. I have no idea what color it will end up this time!
