53 replies to this topic

[hadfield4wd TT Bronze Member]

I’ve been looking for a while.  My biggest problem with the whole thing is the only one I could buy that had everything I wanted was a KTM.  Which I rode and loved.  But they are higher maintenance.  But great bikes.  I looked at one for 3k but it needed another 1k in maintenance to get it where I wanted it.  I do a lot of single track and fire roads.  We’ll be doing some longish hauls but really no more than 3 hours.

The DRZ’s are great bikes, but not enough power.  To do what I would want I'd put a big bore kit one etc.  The KLR's (Kawasaki) are more on road than off road for single track.  The bigger DR's (Suzuki) are great, but most of the ones I looked at were kickstart only.  And quite frankly I didn't want to kickstart a 650 all the time.  The Honda 650L's are way overpriced.

So basically I couldn't find exactly what I wanted.  So while in Abingdon for a couple meetings I had some time between and went to a used motorcycle store.  The guy didn't have any but told me of a guy that may etc, etc.  The rest of the story involves a piercing shop (yes that's what I said) and a beer to finish.  But basically the guy had a non running motorcycle.  So we went and looked at it.  Turns out it was a 1985 KLR600.  Has everything I wanted but a rear disc brake.  I can put up with a drum.  We haggled.  He didn't have a title so I'll have to get that etc.  It has a newer top end according to the motorcycle store owner.  Electric start was an option for that year and this bike has it, along with the kickstarter.  The bike has less than 5000 miles total on the odometer, I have no reason to believe it's not accurate.  It's been sitting for 2 years unused.  The motor is free and is missing some minor plastics.  All available on ebay.  The bike will need and entire teardown and rebuild.  The suspension needs rebuilt.  I'll be putting a 650 shock on the rear with a heavier spring and putting heavier springs in the front forks and changing the oil in the forks.  Then I'll go over every bearing, bushing pivot etc.  The best part is the price.  $200.  These older KLR's are better in the dirt than the newer ones.  Better geometry.  Lighter.  Very similar to the KTM, but less power from the factory.  I'll change that.   I'll get it reliable and working properly then work on the performance aspect.   Here it is.  

When I first saw it.

On the trailer

In the garage.

[hadfield4wd TT Bronze Member]

I'll be needing some plastics and body parts.  As well as technical assitance.  thanks in advance.

[XR_RON TT Platinum Member]

Theres nothing wrong with a project bike,Ive done a few myself.The price was right,Good luck fixing it back up.

[hadfield4wd TT Bronze Member]

Carb is rebuilt.  I've got he tank cleaned and coated.  Going to fire it this weekend to see what happens.

Is it possible to to change the seal at the shifter without splitting the case?  It's leaking oil from there.

Edited by hadfield4wd, 27 April 2012 - 12:22 PM.

[LordYorkshirePuding TT Member]

hadfield4wd, on 27 April 2012 - 03:24 AM, said:

Carb is rebuilt.  I've got he tank cleaned and coated.  Going to fire it this weekend to see what happens.

Is it possible to to change the seal at the shifter without splitting the case?  It's leaking oil from there.

just knock a small screwdriver into the seal carefully so you dont damage the caseing and prise out the old seal slide the new seal down the shaft use a pice of tubeing to knock the new seal home. All done takes about 30 mins

[hadfield4wd TT Bronze Member]

Well the oil seal is done.  Changed the oil.  New filter and plug.  I was able to get all the missing plastics from ebay.  Checked all the bearings and brakes and they are good to go.  I'm getting a stainless front brake line.  I am putting a 650 rear shock on and the springs from a 650 in my forks.  The shock is shorter and wider than the one on the 600.  This is resulting in clearance issues with the airbox.  So I'm going to weld tabs on to lower it.

I'm also working on the plastics to get them cleaned up and treated.

Tank has been cleaned and i have 1 coat of paint back on it.

We fired it last weekend to make sure it would run.  Ran for about 10 seconds on the fuel in the line.

All the lights work as does the cluster.

[hadfield4wd TT Bronze Member]

I got it moslty assembled today.  I do have another question.  I needed a new clutch cable and a mount for a left side mirror.  So I got a newer KLR 650 clutch lever with the mirror mount built in.  Well my clutch switch thingy is totally different.  How do I bypass this?

[hadfield4wd TT Bronze Member]

Never mind on the clutch lever.  Got it fixed.  Pics coimng soon.

[hadfield4wd TT Bronze Member]

My parts showed up Friday but I didn't have time to work on it Saturday due to our exchange students being here.  So I worked until 2am on Friday night.  

Then my friends Gabe and Chuck showed up Saturday morning and finished everything up while I went to the lake with our exchange students.  they knew I wouldn't be here so I guess I owe them.  I buttoned it up this evening.

Here it is.





Pretty happy with it.  I do have some things before my first real ride.  The oil looked like cappuccino even after the change.  So it's either the water pump, or head gasket.  I need to adjust the valves.  And figure out why my temp gauge is not working.

Plus I have a couple more cosmetic things to do.

Other than that it pulled pretty strong.

[hadfield4wd TT Bronze Member]

Also my temp gauge is not reading at all.  It does move but doesn't even come up to the bottom line.  How do I test the sending unit?  My fan did not come on when I grounded the wire on the bottom of the radiator.  So would this be a relay?  Wiring?  What else?  Anybody have an online wiring diagram?

[hadfield4wd TT Bronze Member]

Does anybody know of a place where I can get an aftermarket front fairing for this bike?  Or one I can mod to fit pretty easily.  I want kawi green?

I have a bad fan relay so I'll get a new one.

Edited by hadfield4wd, 26 June 2012 - 03:31 AM.

[hadfield4wd TT Bronze Member]

I've got an issue.  The clutch I'm replacing.  It appears to be wasted.  So I got an EBC.  In doing the change out I noticed there was some play the the basket against the gear on the motor.  I know the inside portion where the discs should turn free, and it does.  But the outer portion that mates to the gear has some play in it.  Maybe 1/4".  Is this normal?  How does the outer portion attach to the crank/gear?

Also we were adjusting valves and realized there is some rediculous spring holding the compression release open all the time.  Looks like it's from a bic pen or something, really!

Also got the eagle mike doohicky deal to fix that.

And ordered a Dunlop606 for the rear.

[hadfield4wd TT Bronze Member]

Does anybody know if the pipes from a klr650 will fit the 600?  I know its single mount versus 2 mounts but anything else?

[hadfield4wd TT Bronze Member]

All parts are completed.  Doohicky, carb (still have some tuning), new brakes, new tire mounted.

I had fuel dumping out of the carb overflow.  Turns out the float leaked and was sunk in the bowl causing the fuel to just run out.  I had another float here so got it in and good to go.

I made a new door for my air box as the one I had was cracked.  I used clear plexi so I can look at the filter without removing the box.  I have a round unifilter versus the stock so I'm passing more air so I also put put n a klx needle, bumped up my main jet and have the pilot adjusted at 2 1/2 turns.

I rode 162 miles Sunday with a friend and did about 11 miles of dirt trails.  Really happy with the performance.  I do need a new pipe though can anybody answer whether a 650 pipe will fit on a 600?  Then I can tune some more on the carb.

[hadfield4wd TT Bronze Member]

My pipe is way too loud.  It's louder than my buddies, 650 with a port and polish, 685 big bore and two brothers E2.  I'll be getting a new pipe shortly, just need to finish the wifes quad.

[hadfield4wd TT Bronze Member]

New Trail Tech

Before

After

[IDRIDR TT Bronze Member]

hadfield4wd, on 20 August 2012 - 10:35 AM, said:

New Trail Tech

Looks good.  When I put one on my KLX, I first turned the tire size on the vapor to 9999 (a very large wheel indeed), and taped one of the magnets to my old electric power drill, set it up so the drill would run and trigger the wheel speedo pickup, and racked up nearly 3500 miles on the vapor in no time which was really close to the mileage on my stock speedo.  Then the drill burned up!

[hadfield4wd TT Bronze Member]

IDRIDR, on 20 August 2012 - 03:06 PM, said:

Looks good.  When I put one on my KLX, I first turned the tire size on the vapor to 9999 (a very large wheel indeed), and taped one of the magnets to my old electric power drill, set it up so the drill would run and trigger the wheel speedo pickup, and racked up nearly 3500 miles on the vapor in no time which was really close to the mileage on my stock speedo.  Then the drill burned up!

I emailed tech support.  There is a way to program the existing mileage.

[hadfield4wd TT Bronze Member]

So I took it to Hatfield McCoy over Labor Day.  Had a great time.  Bike did great.  I did manage to dump it an dbend the original factory bars.  So I bought a pair of Azonic double wall bars off ebay.  Should be here this week.  I also have a bad LED on my trail tech and they sent me new ones.  I also have some heavier front springs to put in.  I also hate my fairing.  Looks very dated.  I think I may purchase the Trail Tech x2 fairing.  Still on the fence.  My fuel cap leaks so I need a new gasket.  This may be a needle in a harstack.

Edited by hadfield4wd, 11 September 2012 - 09:50 PM.

[Sierra Thumper TT Bronze Member]

hadfield4wd, on 11 September 2012 - 09:48 PM, said:

So I took it to Hatfield McCoy over Labor Day.  Had a great time.  Bike did great.  I did manage to dump it an dbend the original factory bars.  So I bought a pair of Azonic double wall bars off ebay.  Should be here this week.  I also have a bad LED on my trail tech and they sent me new ones.  I also have some heavier front springs to put in.  I also hate my fairing.  Looks very dated.  I think I may purchase the Trail Tech x2 fairing.  Still on the fence.  My fuel cap leaks so I need a new gasket.  This may be a needle in a harstack.

I love seeing somebody resurrect a bike thats been sitting its life away in a dark corner, and get some true pleasure out of it I've did that myself to quite a few low mileage dust collectors, and had a ball on them for cheap, then sold them for a profit.
Keeping them and making good memories is even better