Saturday, June 27, 2020
Tuesday, June 02, 2020
KLR250 Full Restoration and Mods
Restorations and modifications I've done on my 1990 KLR250D :
Thermo-Bob 2 for KLR250
Stabilize engine temperature swings and eliminates cylinder hotspots. It is originally a popular mod for KLR650 brother
Kawasaki cut corners in the KLR cooling system, and the Thermo-Bob modifies KLR's cooling system to operate like automotive systems have for decades. In stock form, the KLR runs too cool in colder climate.
Ebay Aluminum Skid Plate for a Kawasaki KLR250 1985-2005
Mojave intake camshaft 12044-1181
As my original intake cam (would have been part number 12044-1119) was worn I replaced it with easily available Mojave cam. It looks to have more aggresive and higher profile. Works very well.
An important note when changing camshart is to
- Change the follower at the same time
- Use specialised cam assembly lube liberally (not just oil)
- Running in process of fluctuating around 3000RPM for 30 minutes to seat the cam and follower
I did not do those and was worn again soon
Immix Racing cargo carrier
From Amazon:
Barrett products pannier hoops
I bought these plain hoops and mount it easily using steel plates
Mounting it: https://www.youtube.com/watch?v=OtP2BAbPFj0
Ebay 5L motorcycle jerry can
Very robust and strong mounting. I've crashed on to it with no problems
Ebay Heater Grip
"7/8 inch 22mm Motorcycle Universal Heated Molded Handlebar Hand Grips Warmer"
It's got 4 temperature settings which can be operated using left hand. I connect it using a relay patched to the day running light cable
T-Mod
To prevent carburettor to starve from fuel when doing water crossing, add a plastic T-connector on the breather hose
Ebay Generic X-Grip motorcycle mount
Very strong and has already got a USB charger to make a neat installation
Ebay Cigarette-lighter and USB charger
Cigarette lighter socket to power up tyre pump etc and 2 USB charger.
Some versions have voltage indicator also. I wired it directly to the battery as it's got a switch. Useful when the motorbike is not running
Oxford OL200 Topbox 24ltr
From Ebay: https://www.ebay.com.au/itm/153508124910
Tubeless tyre mod
Using generic tube to convert the spoked rim to Tubeless tyre
Front gear 13T
The stock 15T is great for all-round road and dirt. I've tried 16T and it's great if you do 110kph+ trips
13T is great for dirt and climbs enduro tracks
Supercheap ToolPRO 300mm
Great to organise toolbox, tyre lever etc. and can move between bikes quickly
Tyres
My main criteria is 50/50 handling and ease of installation, in case I need to fix punctures on the road. The compromise of softer compound is tyre life
Rear: Dunlop D605 4.6-17
Front: Continental TKC80
KTI Personal Locator Beacon (PLB)
Emergency locator, hope I never have to use it but necessary when heading into remote areas
KLR250 Service Manual
I always carry a .pdf copy of the service manual on my phone... just in case. You need the base manual as well which is actually a KLR600 one.
Download link:
Others
Archive of old KLR reference page:
Monday, June 01, 2020
Kawasaki KLR650 Tengai Restoration and Mods
Restorations and Modifications I've done on my 1990 KLR650B Tengai:
Full Crash Bar
Custom-made by "Evil Chop" facebook manufacturer from RomaniaHowever I heard that he's not making them anymore except for group buys
EagleMike Doohickey kit
https://www.eaglemike.com/Complete-kit-w-torsion-spring-less-tools-clkwtslt.htm
In Australia it's available from AdventureBikeAustralia website:
https://adventurebikeaustralia.com.au/product/doohicky-kit/
In Australia it's available from AdventureBikeAustralia website:
https://adventurebikeaustralia.com.au/product/doohicky-kit/
Upgrade to the weak stock Balancer Chain Adjuster Lever which could destroy the engine.
You need a special wrench (or easily make one) to install it
Thermo-Bob 2
Stabilize engine temperature swings and eliminates cylinder hotspots
Kawasaki cut corners in the KLR cooling system, and the Thermo-Bob modifies KLR's cooling system to operate like automotive systems have for decades. In stock form, the KLR runs too cool in colder climate.
Centre stand
Ebay "Kawasaki KLR650 CENTER STAND 1987-2018" from seller carlspowersportssupply
Note that:
The "step lifter" will hit the passanger footpeg bracket. I just simply shorten it by few cm's.
The rear wheel would not lift sufficiently without the extension but installing it will make lifting the bike difficult. I don't install it and just put a rock once the bike is on centrestand. Much easier
Ricochet bash/skid plate
From MXStore Australia
Eaglemike KLX Jet kit
Improves the fueling of KLR650 to be less tractor-like and more linear feel throughout the rev range.
This is fully-reversible jetting change with no need to drill etc
Happy Trail racks and panniers
I bought the "gen-2" rack as it was available cheap locally instead of shipping from the USA.
The gen-2 rack does not fit Tengai perfectly, only one rear mounting is able to align.
Note that both gen-1 and gen-2 racks will require a tab to be welded to Tengai's subframe - or if you're lazy like me just use pipe clamp. It' secured enough
Ebay Heater Grip
"7/8 inch 22mm Motorcycle Universal Heated Molded Handlebar Hand Grips Warmer"
It's got 4 temperature settings which can be operated using left hand. I connect it using a relay patched to the day running light cable
T-Mod
To prevent carburettor to starve from fuel when doing water crossing, add a plastic T-connector on the breather hose
Ebay Generic X-Grip motorcycle mount
Very strong and has already got a USB charger to make a neat installation
Note: updated with Wireless (!) charger which works very well and obviously no more worries of charging in rainy conditions:
Ebay Cigarette-lighter and USB charger
Cigarette lighter socket to power up tyre pump etc and 2 USB charger.
Some versions have voltage indicator also. I wired it directly to the battery as it's got a switch. Useful when the motorbike is not running
Ebay 52L Top box
Great capacity but the latching to base is not strong enough for dirt riding/pot holes and mine had came off once. I ended up bolting it permanently.
https://www.ebay.com.au/itm/52L-Motorcycle-Storage-Box-Luggage-Scooter-Topbox-Rear-Top-Tail-Latch-Secure/184200063416?hash=item2ae32de9b8:g:hkMAAOSwd5FeYl50
Tubeless tyre mod
Using generic tube to convert the spoked rim to Tubeless tyre
Front gear 14T
The stock 15T is great for all-round road and dirt. I've tried 16T and it's great if you do 110kph+ trips
14T is great for dirt and you lose 5kph and ended up doing 95kph at 4500rpm on freeways.
Note that Tengai's front sprocket is much thicker than KLR650. It's got 12.8mm thinckness
Supercheap ToolPRO 300mm
Great to organise toolbox, tyre lever etc. and can move between bikes quickly
1" Raising link
Added 1" ride height to reduce scraping using 121mm raiser:
The raising link raised the bike to 1" and also contributes a firmer feel to the spring.
Top Gun 7.4kg Rear Spring
On fast dips and fully loaded the rear bottoms out frequently. For my 91kg of weight I upgraded the rear spring using Top Gun 7.4kg replacement
Youtube video of the process here:
Tyres
My main criteria is 50/50 handling and ease of installation, in case I need to fix punctures on the road. The compromise of softer compound is tyre life
Rear: Dunlop D605 4.6-17
Front: Continental TKC80
I convert them to tubeless as per video here:
KTI Personal Locator Beacon (PLB)
Emergency locator, hope I never have to use it but necessary when heading into remote areas
Tengai Service Manual
I always carry a .pdf copy of the service manual on my phone... just in case
Download link:
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