2022 Kawasaki KLR 650

[Flyin6]

In lieu of doing a bike build on my adventure thread which I am saving for trip pics, I'll just build the Kawasaki here.

I thought I'd keep this one sane and simple and inexpensive. After all the KLR is an adventure bike costing 1/2 to 1/3 the price of its competition that it really does not have.

So job1 will be to just buy less or the least expensive parts. I have found that you can pay double, triple or more if you are going for the snooty very best of the very best. Come down a paltry 10%-20% in capability, or quality and you are looking at half to a third the price. So you get a lot of bang for the buck for a much lower price point.

Next, keep it sane and focused. For this summer/fall, the pre-ranger will essentially be learning. So we aren't going to do anything crazy. We have to get good on the street, get good at low speed riding, and somewhat proficient on easy trails, two and single tracks.

So, it already has everything needed to be a good commuter and street rider, so it really needs very little there. I was thinking a throttle friction device to serve as a poor man's cruise control so I can get my hands off that buzzing bar every once in awhile. Oh, and I'll need a GPS/Phone holder so I'll score one of those.

For trail riding, I already think the stock rubber foot pegs are a non starter and with my height, standing and riding in the attack position forces me to lean slight forward placing more weight over the forks. That's not good, so I'll have to raise my handlebars. Next up it needs just a touch of armor. I am thinking a good bash plate and maybe just ride that for awhile before deciding to buy crash bars.

It already has panniers although they are small at 21 liters. They never the less fit the bike so I'll see how to develop that. I'll need some tools and things like a spare tube or two, an inflator, some irons, a hillbilly center-stand, some duct tape, spare nuts and bolts, and locktite.

I always like a bit of an exhaust note so I think I'll lead off this build with a cool exhaust.

[Flyin6]

Just for fun, I went on Amazon and searched KLR650 thumper exhausts.
They had a bunch
So my search criteria was to find the least expensive one I could find.
Where these things normally run close to more than $500, for a paltry $219 I scored this Delkevic American made stainless can

[Flyin6]

Exhausts are always fun on bikes so after it I went. First documenting what the gaudy stocker looked like, I proceeded to remove it starting with the Pannier and the side plastic. That came off in maybe five minutes. Three screws and the turn of a key and those parts were on the floor!

[Flyin6]

That stock exhaust was big and heavy (guessing 15-20 pounds) and even had a heat shield

Taking this apart, I started to really appreciate Kawasaki's build quality

[Flyin6]

Look at this boat anchor...Huge. The bottom half is a catalytic brick, thus the need for all the heat shrouding.

[Flyin6]

The new exhaust was on in just minutes, including applying some supplied high temp RTV

[Flyin6]

That won't get anywhere near as hot as the stock piece did. No cats, lyticing in there. Notice the muffler has a silicone gasket on the clamp? Really how hot can it get. Anyway the factory plastic has a layer of heat shielding

[Flyin6]

That took three screws, allen head, thank you berry much, and it was back on...

[Flyin6]

I tossed the pannier back on. That takes 10 seconds max and it was tool clean up time

I punch of the starter button and right off I was reminded why these big singles are called thumpers. What a powerful exhaust note. No hiding from anything from here on out...

[Flyin6]

The exhaust wasn't the first thing I did. I raised the windshield 2", and cut off two gaudy reflectors, and of course added my obligatory decals so everyone will think I am somebody...or not.

I'll bet no one gets the one beside the 101st patch. No sir, that's a rare one right there...

[Bigdave_185]

Is there any further restriction on the exhaust header?

Air filter upgrades?

I assume it’s EfI.  Can you get a programmer for MO POWER!?

How does it handle the weight of you and wife?


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[TexasRedNeck]

I would assume that the stock EFI feedback loops would have some ability to adjust AFR within a certain range, so freeing up exhaust and intake (K&N) should increase power to a certain amount.

https://procycle.us/model/kawasaki/klr650/controls

Might look at a vibration isolation bar riser set up to help with the buzzing

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[Bigdave_185]

Now that’s a good idea! I put some bars in my off-road bike that did the similar idea and it made an enjoyable improvement

I have not put a pair on my current bike but the Seemed to work as designed

https://dirtbiketest.com/product-tests/brp-4-post-rubber-mounted-triple-clamp/


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[Flyin6]

Is there any further restriction on the exhaust header? No, Mandrel bent header pipe all the way back. No restrictions I can see

Air filter upgrades? None at this time

I assume it’s EfI.  Can you get a programmer for MO POWER!? Yes you can. Spendy, like $500 and this bike doesn't make much power, so not sure it would benefit...Adding a little to not to much already and all that. Besides, part of its character is this lumbering great old ADV bike from the 80's. I don't think it needs to be powerful.

How does it handle the weight of you and wife? Never had anyone but me on it. KLR's are known to be soft sprung. Gen 1's way too soft. Gen 2's got a little stiffer spring. I hear this new Gen 3 got a bit more spring and some stiffer valving. No plans to ever ride two up except to take grandkids down the field they live next to.


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^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

[Flyin6]

I would assume that the stock EFI feedback loops would have some ability to adjust AFR within a certain range, so freeing up exhaust and intake (K&N) should increase power to a certain amount.

https://procycle.us/model/kawasaki/klr650/controls

Might look at a vibration isolation bar riser set up to help with the buzzing

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It's not bad at all. Only starts to annoy after 30 min or so. I already ordered 2" Roc Risers and a cruise control friction thingy

[Flyin6]

Today in between mulching flower beds, pulling weeds and cutting grass, I took maybe 30 minutes to install one of Enduro Engineering aluminum bash plates

It is one well built piece. They didn't have one in black, so I just picked up this straight-up aluminum piece

[Flyin6]

4 8mm head screws later and the factory plastic piece was off. Looking at it after removing it, I have to say, it is pretty robust. That plastic is something roughly akin to what Glocks are made of. I'd say it could take a decent hit. but not a sharp rock, and the KLR oil drain plug has a thick head which pokes its head downward a bit too much. I never liked seeing that down there just waiting to get hammered into the case cracking it and leaking all the oil out.

[Flyin6]

The skid plate did not mount into the same holes as the factory one did according to the directions. The Adventure models have an engine crash bar which bolts into the frame further aft. That Enduro Engineering piece actually had holes for the crash bar mount, so I just found some longer bolts and used that mount.

The oil drain plug is now recessed and safe.

Nice little 30 min job

[Bigdave_185]

I know you will love this but if you pull that metal plate back off and add some of that aluminum foil backed sound deading stuff to it.  You will block a large amount of motor noise.   I have added these skids to every bike I have rode and they work great with the exception of the sound reflection from them.

Well worth it!


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[Flyin6]

I know you will love this but if you pull that metal place back off and add some of that aluminum foil backed sound deading stuff to it.  You will block a large amount of motor noise.   I have added these skids to every bike I have rode and they work great with the exception of the sound reflection from them.

Well worth it!


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Very well then. I'll go buy some and the next time the plate comes off, I'll make it so...Thanks

[JR]

Fluid change has begun!!

[Flyin6]

Did a bunch more...took pics, downloaded them onto this new MacBook...Now I can't find them
I don't like Apple laptops yet!

[stlaser]

Wife has had hers for a couple years and still dislikes it…..

I have a 7 yr old windows Lenovo, no issues yet

[Flyin6]

Wife has had hers for a couple years and still dislikes it…..

I have a 7 yr old windows Lenovo, no issues yet

My 10 year old windows 7 ASUS has a hard failure. Displays a message saying something has failed and the computer can no longer communicate with itself or something like that

[JR]

They can pull the stuff from it.

I like windows

[Sammconn]

Wife has had hers for a couple years and still dislikes it…..

I have a 7 yr old windows Lenovo, no issues yet

My 10 year old windows 7 ASUS has a hard failure. Displays a message saying something has failed and the computer can no longer communicate with itself or something like that

You should be able to pull the hard drive and use an external reader hooker upper thing. Based on your description I think it sounds like a bus failure so your drive is maybe ok to read still.

[TexasRedNeck]

I don't like Apple laptops yet!

Neither does Hunter Biden


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[Flyin6]

I don't like Apple laptops yet!

Neither does Hunter Biden


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His was a Mac?
Figures...

[Flyin6]

Did I mention I don't like MacBook or Apple computers/phones/politics/anything.
Fell for it. Listened to my friends, "Apple is so easy, you just sit down, it reads your mind and does all your work
Poppy Cock!
To resize an image in windows. You click on it, right click it, select your size, then enter, and it's done.
This POC, you open some program up. Then you open photos up. You'll probably have to enter a password or something because this POC detects someone, probably an unauthorized user (never) then you have to highlight and drag the photos to this other program and drop them. Then select some custom size. Don't know about you, but I don't have the time to memorize what size equates to what quality.
Then you resize to some custom size, then export that file. I had to create a new folder and that of course is NOT in the photos folder, I mean, why should it be? Photos ought to be in a document or Excel file or maybe some other never seen before application. So you have the pics resized and you've developed an age spot.
No telling if you can ever find that file, but there is a large partitioned section of the hard disc named "The Twilight Zone." Lots of stuff goes there and that's where the 76 passwords needed to do anything are stored.
So you glance down and there it is, a second age spot and you notice several days have passed and your wife left you because you haven't spoken to her and ll she hears from you are curse words.
At this point who gives a flip about and gosh darn pictures anyway? I just want to kill some software engineer, R e a l. S l o w.
I don't even know what I'm doing here. I was trying to do something a couple days ago, but with the wife living me and the six new age spots, I just want back in Afghanistan with a minion. Heck, skip that, I'll only need a sharp stick and some time. But time is something I no longer have any of thanks to this F#_)$!! Apple POChit!

[Flyin6]

I'm not better but I wanted to load some of the lost pics to show what I'm doing to the bike.

I replaced the factory pegs with some cheap enduro pegs which were lighter, bigger, easy to install, and cheap

[Flyin6]

One thing I will say is that somehow the apple iPhone automatically downloads the photos I take onto the Mac block confuser and time waster and absolute joke of a computer.

So, next I pulled the factory hand guards which had zero protection and were really just wind guards, and installed some real-deal bark buster guards

[Flyin6]

Finally, I screwed on a phone holder and added a power chord. This holder is substantial. It's like working out stretching those padded fingers wide enough to fit the phone. I half expect them to crush the phone to dust during some ride...We'll see

[JR]

If its an Apple phone, whats the harm?

I need mounts for my tractors. Digging it from my pocket is a joke and I normally have gloves on.

[KensAuto]

I got this one for the mini dozer JR. This one has a strong magnet. Not cheap but worth it imo. I have a spring style in the excavator but it gets dirt in it and makes it not open/close.
Mob Armor Mount Switch - Magnetic... https://www.amazon.com/dp/B01BINV9P2?ref=ppx_pop_mob_ap_share

[Bigdave_185]

Looks good except that phone mount looks sad in my book
I’m more of a positive retention kinda guy.

This here isn’t going to toss your expensive phone into the bushes at the first good jar of a tree branch+barkbuster contact.

Quad Lock Motorcycle Handlebar Mount for iPhone and Samsung Galaxy Phones https://www.amazon.com/dp/B08741BFFC/ref=cm_sw_r_cp_api_i_CBXQZVYMQS15RQ1EHDZ9

Just sayin.

I actually don’t mount my phone on my trail bike, it’s in a padded zipper pocket hidden behind my bars because I have seen phones on bar mounts get smashed in wrecks.  No call for help ( if ya had service anyway) when the phone is destroyed


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[JR]

I have a case on mine so something like that won't work Dave. Magnet is cool, but $60 for a holder isn't.

Sure there is something, just haven't looked real hard yet.

I like the pegs Don, shoes slide off wet rubber!

[Bigdave_185]

I have a case on mine so something like that won't work Dave. Magnet is cool, but $60 for a holder isn't.

Sure there is something, just haven't looked real hard yet.

I like the pegs Don, shoes slide off wet rubber!

That’s why you get the matching case jr.  A magnet is just as Likely to fall off with a solid bump.

If I can loose a orange flag on a 75lb rated magnet I wouldn’t put my phone on it.


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[Flyin6]

Looks good except that phone mount looks sad in my book
I’m more of a positive retention kinda guy.

This here isn’t going to toss your expensive phone into the bushes at the first good jar of a tree branch+barkbuster contact.

Quad Lock Motorcycle Handlebar Mount for iPhone and Samsung Galaxy Phones https://www.amazon.com/dp/B08741BFFC/ref=cm_sw_r_cp_api_i_CBXQZVYMQS15RQ1EHDZ9

Just sayin.

I actually don’t mount my phone on my trail bike, it’s in a padded zipper pocket hidden behind my bars because I have seen phones on bar mounts get smashed in wrecks.  No call for help ( if ya had service anyway) when the phone is destroyed


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I like that!
I think I'll switch to this thing and put the other mount in the Kubota SVL-97
OK, so where is the case?

Edit: Its ordered

[Sammconn]

Looking good chief.

Now on the MacBook thing.
My wife fell for it too, our boy was the big pusher of his “easy” it all was.
He now has said MacBook.

[Flyin6]

Looking good chief.

Now on the MacBook thing.
My wife fell for it too, our boy was the big pusher of his “easy” it all was.
He now has said MacBook.

I hate the thing so far.
But
Staying with it.
I feel similarly about our president, but for the next almost three years, I'm stuck with him too
Its like that
So anyway, I raised the handlebars with the 2" ROC Risers

[Flyin6]

Its a simple enough install. Loosen four handlebar clamp bolts, then install the ROC risers, then reinstall the handlebars into the saddle of the risers, then reposition the bars

[Flyin6]

Installed:

[Flyin6]

Everything clears

Before/after:

[Flyin6]

Next up, I installed some front fork stabilizers

[Flyin6]

You pop out the dust boots, then install the fork braces into the recessed spot, then slip the boots back on. Really nice modification

[Flyin6]

Handlebars finished off with a TUSK bump pad

[Flyin6]

Finally, I zip-tied the brake line to the swing arm

[Bigdave_185]

Not to be “that guy” again but

Notice your handle bars have some knurling on them.  That is so the clamps have something to bite into.  The bar riser you installed are a smooth shaft on smooth clamp aluminum on aluminum. It won’t take much for them to slip.   You can remedy this by adding some metal mesh screen window material.  Has to be metal but will provide loads more friction

The ideal solution would be to simply order some high rise bars that will accomplish the same thing.  You can get bars with more sweep or less sweep taller or shorter.  I prefer ProTaper bars on all my stuff

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[Flyin6]

The handlebars have two circles of knurling that is clamped by the risers. A little protruded because of how the risers fit. It's good, and I know about that...been riding more than 50 years, but thanks anyway

[JR]

Glad you fixed the rear brake line. I remembered from the first pictures and it hanging low caught my eye, just kept mum though.