Modded the KLR some tonight
 

I did a small job on the bike tonight, replaced the crappy grade 2 subframe bolts that sheer often and easily with a single grade 8 upper bolt that is double the thickness and two grade 8 lower bolts. Took me almost an hour and 3 size drill bits to drill through the frame to get the larger bolt through. Also added some brush guards to protect the lever in a drop, and a throttle lock to the handle bars.

I have a heavier rear spring and a shock rebuild & revalve kit in a box waiting to go on the bike too, thats gonna wait until I see how the bike handles riding with a load this weekend, but I expect to add it on sometime in the near future.

Drilling the frame out

http://sphotos.ak.fbcdn.net/hphotos-..._2431901_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-...2_982515_n.jpg

And the handle bars, gonna put the stock plastic hand guards on it once I get the bolts to hold it on tommorrow.

http://img809.imageshack.us/img809/3...1006002751.jpg

http://img28.imageshack.us/img28/590...1006002809.jpg

And while the gas tank is off I need to figure out why the power to the 12v outlet cuts off and on randomly, I am pretty sure I got a bad connection or loose wire somewhere. I tried to use my audio system last weekend and it would work for a few minutes then turn off and turn back on, on its own.

sweeet

this is what tends to happen when the subframe bolts aren't upgraded


http://www.jahkola.net/mp/tengai_maintenance.htm

http://www.jahkola.net/mp/IM002260_560x199.JPG

http://www.jahkola.net/mp/IM002265_331x248.JPG

Nice.. yeah I had a few preventive maintenance items to fix when i first got the bike...

the only thing I got left is to put in an easy to reach bypass for the clutch kill switch, thats another part that historically goes bad. i dont want to get rid of it completely, just add in a plug inline so that I can bypass it if I need to. I already did it with the kickstand kill switch, the wires just plug into each other if it fails.

http://sphotos.ak.fbcdn.net/hphotos-...4_218848_n.jpg

those are two I haven't done yet... figure they're both easy enough to do on the trail if it fails.... and I have electrical tape and wire in my tool kit. but no issues yet

I figure its easier to just unplug/plug back together than cutting away wires on the side of the road. it took 10 minutes to do in the nice warm area I call my garage

Well, an ounce of prevention is worth at least a pound of low grade Mexican.

Nice job man

Nice work man! I need to get the subframe upgrade bolt kit still and do it while I've got the bike apart.

I did some work tonight myself. Bought a press and got all of the triple tree, subframe, and suspension link bearings out by myself.

The dealer can suck it! The ONLY thing I need now to be a complete in-house work on my own bike shop is a tire changing machine. Coming this winter I assure you.

nice.

Yeh the subframe kit was easy as hell to do, just took time, almost 2 hours start to finish. It would have helped if I didnt run out of machine oil as soon as I started, but apparently chain lube makes a decent substitute. Really, I just took my time, gave the bits plenty of time to cool off, and used an extra intermediate drill instead of jumping from the small supplied bit to the large one. I also was able to drill the hole straight enough that I didnt need a hammer to knock it in, it just slid in like it belonged :rockwoot:

Good preventive stuff. I love working on my bike. I don't care how big or small the problem. It just makes me feel better. It's my therapy

Got to luv drillin on the frame! LOL

Your camera SUCKS! Holy shit.

What has been done cannot be undone, but it worked out fine so its all cool

cell phone

I got it at Harbor Freight. It's on sale right now for $129.99.