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The Fleet
So instead of posting different threads for each of our toys I'll post one thread with all.
For starters, I'm a kawasaki fan. Been that way since watching Jeff Ward. no good reason actually just loved them and that's that. So basically, for the most part, I can't go out and buy a perfectly good, "no-issue" bike. They have to be projects or basket cases. 2 exceptions are my BMW and the gasgas. I also really enjoy working on stuff. I used to build rock crawler chassis and jeeps/buggy's. Anyway I'll do my best here not to jump around too much. I've done a halfway decent job of documenting all the builds. Here is what I'll be sharing. (BMW will stay off the list because it's boring, nothing ever breaks or fails.) Everysingle one of these has been a basket case, or project. Most mean shoptime with a family member. Wife helped on her Rancher. Son's on their projects. 2003 Honda Rancher 2004 Yamaha Breeze 1986 Kawasaki KL 600 1989 RM125 1998 Kawasaki KLX 340R 1997 Kawasaki KLX 300R 2004 Kawasaki Mojave 250 |
The '03 Rancher basket case. I got it as a rolling chassis and the parts in 6 rubbermaid containers. We determined 1 of 3 things happened to this. 1) It rolled down a cliff. 2)It fell out of the back of a truck going down the highway. 3) It was in a an Asian mudslide. We're going with mudslide and the rear diff was full of mud (it must have been run that way for a while so we had to replace it.)
My buddy has been working on it tons and I come over when I can. Its now a runner with a .25 overbore. ITP Rims, holeshot fronts and big Bear rears. We call it the Rancher SQ (Sport Quad :dry:) We're going to go no racks as they were bent to crap. The bars too so we bought new ones. I'm going to put a rear, grab bar/wheelie bar/bumper on. Right now we have it all working. Except the e shift. The "N" keeps flassing 3 times. So we're cleaning up the angle positioner thing to see if that helps. I can always swap the ecus's to see if that the problem as well. http://i85.photobucket.com/albums/k5...ycle/quad2.jpg My wife getting into it. http://i85.photobucket.com/albums/k5...cycle/quad.jpg My buddy http://i85.photobucket.com/albums/k5...06F41542FC.jpg http://i85.photobucket.com/albums/k5...06E8D1818A.jpg What it looks like on a Wednesday before a weekend at Hatfield McCoy http://i85.photobucket.com/albums/k5...06DD7C9704.jpg |
I picked up this '99 Yamaha Breeze 125 for my 10 year old. $325
Fits in the old manvan http://i85.photobucket.com/albums/k5...4B7219DA54.jpg I already have it stripped. Brakes and bearings ordered. Having them delivered next day so I can get it together and test ridden before our Hatfield McCoy ride this weekend. http://i85.photobucket.com/albums/k5...4C01986327.jpg |
He's working on his own junk this was 4 years ago.
http://i85.photobucket.com/albums/k5...5A9FC67F84.jpg His needed tires, a foot rest and some other parts. Turns out there was another one on clist with a blown motor. Paid $150 for it. The tires are worth that. Also his is making a loud racket in the transmission area. So I'm working on it today. We are supposed to leave tomorrow AM. I had some parts sent next day from rockymountainatv. They should be here this morning. Hope it's not a failure. And no I don't have time to take the parts from the new one I bought last night to put in this one. Last night at 9:30 on the trailer. http://i85.photobucket.com/albums/k5...5AB7DC3EDE.jpg And the wife's 350 Rancher SQ Needs side plastic on the other side so this is the side we take a picture of. http://i85.photobucket.com/albums/k5...5AAA20A680.jpg |
Didn't get the Yamaha running. He was pretty bummed. So was I. I need to split the case. Tranny is bad.
The wifes rancher I think lost a head gasket. It was down on compression and burning oil. But kept running. It's a Honda so what do you expect. I'll get an OEM Gasket for it. she did manage to flip it twice. Bent the new bars a little. And bruised up her elbow pretty good. She's getting more protective gear. Took the motor apart last night. Bad piston. It was rubbing against the cylinder wall. The rings are basically welded into the piston. So the cylinder goes back to the machine shop today. I hope he can tell us what went wrong. As he just did the machining and rings on the piston and we did the assembly I'm not expecting nor asking for anything from him. I'll have to get a 1mm overbore this time to get the scoring out of the sleeve. Lousy cell phone shot http://i85.photobucket.com/albums/k5...ps65c16c3f.jpg Crank was bad so we sent it out. Motor is apart. http://i85.photobucket.com/albums/k5...322D1A0D4D.jpg New piston. Pro-x 1.5mm overbore http://i85.photobucket.com/albums/k5...323D2E76FD.jpg |
Before
http://i85.photobucket.com/albums/k5...5BAFD1A1D3.jpg After http://i85.photobucket.com/albums/k5...5B9F7989C5.jpg The wifes rancher is all together. I'll get the rings broken in tomorrow. My youngest's Yamaha is almost together as well. The engine is together and the jug is on with valves adjusted. Just need to reassemble. So this is what it looked like Friday night. http://i85.photobucket.com/albums/k5...6590602536.jpg Then Saturday around 2. (video) http://i85.photobucket.com/albums/k5...65A54F04B8.jpg The youngest's first ride. http://i85.photobucket.com/albums/k5...65B24319F5.jpg All loaded up for tomorrow. http://i85.photobucket.com/albums/k5...65BFAC076D.jpg |
Better pictures of the wasted piston.
http://i85.photobucket.com/albums/k5...psec1660bb.jpg http://i85.photobucket.com/albums/k5...psa4d3b9cc.jpg http://i85.photobucket.com/albums/k5...ps06a64a4d.jpg And I took better pictures of the new rod on the crank as well. http://i85.photobucket.com/albums/k5...ps81fa6a00.jpg http://i85.photobucket.com/albums/k5...psb9053313.jpg |
I got a 2004 Mojave for $250. According to owner had a "blown motor". It would run but white smoke. Checked oil and it looked like capacino.
This is for my youngest son for when/if he ever grows. He's 13 weighs 85lbs and is 4'11". Grew 3/4" in the last year. Getting new: Rings Cylinder honed New clutch springs (3mm too short - this is curious) friction plates are in spec Engine Gaskets Water pump gasket Timing chain (had a slap) so while I'm in it it makes sense to change it and the guides. That should clear up where ever the water was leaking over to. Plastics need a good cleaning and refurbishment. Dude tried to paint them black. :MattH: As it sits. http://i85.photobucket.com/albums/k5...pswcmmyb6c.jpg Piston looks steam cleaned. :mrgreen: http://i85.photobucket.com/albums/k5...ps24ods2be.jpg Hopefully I'll have all the parts by the end of the week. |
Piss me off. Gasket doesn't line up. This is for one side cover all the rest are good.
http://i85.photobucket.com/albums/k5...pswqzdbkvb.jpg Would have been running otherwise. Athena made the gasket situation "right". Great company and very happy with there resolution. They couldn't make there's work so they bought me an OEM gasket. |
Here is Elijah's first time with a kickstart and clutch.
https://www.youtube.com/watch?v=o16p4jdtKys https://www.youtube.com/watch?v=rqc929Vd1_I https://www.youtube.com/watch?v=gVqW7Yi5Oi4 https://www.youtube.com/watch?v=FUBNJptwRfM That's it for now. I'll do the bikes later. The Breeze got traded for my GG so that was a huge win. |
Wheres the KX 500!
KDX 200? Never seen a Kawasaki nut without a KX 500 or a KDX, if not both. |
Quote:
Haha my friends and I have a KDX "buddy" bike. I'm not really a fan of the chassis. I had considered building a hybrid kx125 with kdx motor. But my GG is a way better bike. KX500 is on the list to own. I want a SM though!! |
Starting with bikes no longer in my stable.
My son's first dirt bike. 1989 RM125 Picked up this 1989 RM 125 to work on with my 14 year old. Motor is in a Rubbermaid. http://i85.photobucket.com/albums/k5...pse43aed0d.jpg He also had a cr250 chassis he wanted to unload. Fit in the back of the burban. No motor. This was used for various projects and ideas. It's a whore, everybody gets a turn. http://i85.photobucket.com/albums/k5...ps8f868c8b.jpg Picture of the garage before I put these 2 bikes in it. http://i85.photobucket.com/albums/k5...ps6d6c6752.jpg First order of business is strip the frame and get it painted then put it all back together. The motor will need a top and bottom rebuild. We’ll rebuild, fix or replace anything we find that is bad on the rebuild. He was pretty excited, still had his shin guards on from soccer practice. Lost the rear fender on the ride home which is OK because it wasn’t the right one anyway. He likes the ’92 graphics that are on it so those will stay. http://i85.photobucket.com/albums/k5...ps49f8736a.jpg So we got it stripped and off to sand blasting on day 1. http://i85.photobucket.com/albums/k5...ps42dae816.jpg http://i85.photobucket.com/albums/k5...psa8a0b1a7.jpg |
Frame is blasted.
http://i85.photobucket.com/albums/k5...psa18f4123.jpg I ordered the Clymers manual as well. Quote:
So we’ve been going through the parts. The big thing is a previous owner has installed a steel sleeve. It needs bored. Which you can do with a steel sleeve within reason. There is no piston in the Rubbermaid that the motor was in so I don’t know what it’s been bored to. It’s been bored to the maximum I can get a piston for. So I was left with a couple of options. New sleeve or have this one Nikasil coated. PowersealUSA comes highly recommended and they claim they can coat a steel sleeve. I think this is the best route so it’s off to them. Also the rod and crank bearings are shot. I’ve had great luck in the past with MRcrankshaft.com. He did my Rancher crank and also the one on my KDX motor that’s going in the CR. And he is less expensive. I sent him my old crank on Friday. He’s already called to say it’s done. New OEM crank bearings and seals are on the way. I won’t order the piston until I hear from Powerseal. Triples are back on. Fork rebuilt waiting on fork boots so I can put them in. Also parts on order. Front tire Swing arm bearings Grips Hand Guards Handlebar Carb rebuild kit 8oz flywheel weights |
Time for some updates. I split the case and sent the crank to MrCrankshaft.com for a rebuild. I also replaced the crank bearings. Leaving the case in the garage and the bearings an crank in the freezer. Makes it all go together pretty easy. I also replaced the swingarm bearings. I have a new (to me) front tire on. The forks are cleaned out and fluid changed. The seals seem to be in good shape so at this point I’ll leave them. If they start to leak I’ll replace them. New grips, handguards, handlebar, rear fender. Also I have 8ox of flywheel weights installed. Any bearing that hasn’t been replaced has been cleaned and greased. I’m waiting on a spoke for the rear wheel. One is missing and so is the nipple so I can only imagine that it was left off by somebody on purpose. I also need the cylinder back and then order a new piston.
http://i85.photobucket.com/albums/k5...ps536a901c.jpg http://i85.photobucket.com/albums/k5...ps0aa2b60e.jpg http://i85.photobucket.com/albums/k5...psab59d47a.jpg http://i85.photobucket.com/albums/k5...ps6ed25f55.jpg http://i85.photobucket.com/albums/k5...ps18f52677.jpg http://i85.photobucket.com/albums/k5...psc1887552.jpg http://i85.photobucket.com/albums/k5...psc6f1d273.jpg http://i85.photobucket.com/albums/k5...psc54cf298.jpg |
So the bike is done, almost. Got it together and it rode great. My son did pretty good. We rode Pedlar. There were a lot of firsts for him. First time on a dirt bike, let alone a peaky 125 2T. First time on anything with a clutch. First time with foot shift (his quad was e-shift). He did pretty awesome. Started to learn to slip the clutch a little
I flogged it at the end of the day after he was easy on it all day on the “break in”. I was really happy. I know why people like the vibration dampeners on the bars. It’s been about 25 years since I’ve ridden a 2T. The suspension did great. Soaked up the 5’-6’ jumps without bottoming. I did run it pretty quick into the corners downshifting with lots of braking and coming out hard on the throttle. I need to work on my clutch work it was pretty bad. I heated up the front brake enough to boil the fluid and lock it up. I tried making it back to the parking lot slowly as I didn’t have any tools on me. I made it to just before the gate and the left turn in the loose gravel pushed the front tire out and I wrecked. Overall I’m very impressed with this bike. We’ll get years of service out of it. Just going to fix the front brake and replace the bars I bent. And a little post ride maintenance and be good to go. These are pictures after the ride so it’s a little dirty. It needs a kickstand too. http://i85.photobucket.com/albums/k5...psd75ac5b8.jpg http://i85.photobucket.com/albums/k5...psc424261b.jpg http://i85.photobucket.com/albums/k5...psa99e0b13.jpg http://i85.photobucket.com/albums/k5...ps82bc2e29.jpg Calebs first ride. http://youtu.be/m3pmHa9qauE |
So we’ve been doing some riding. We were still having issues with the front brake sticking and locking up. So I rebuilt the caliper. Turns out one of the pistons had a bad o-ring that was jammed between the piston and wall causing it to seize up.
Also it’s got an oil leak. So countershaft seal and shifter seals are on the way. Fork seals are blown a well those are here. I’ll get all this knocked out shortly. Got all the leaks taken care of. New fork seals. My son rode it Saturday and Monday this week. He’s getting the hang of it. He’s been short shifting and yet to really stay in the powerband. So on the road that approaches the trail I told him just to stay on it. He finally found it. The smile on his face was great. He’s working on his clutch work as well. He’s still a little nervous to jump it, but on the wide open trails he’s not nervous to open it up. On one trail on Monday he found the power band and traction (it was very muddy) at the same time. Looped the bike right off the trail. Fortunately he bailed off. In the far left bottom corner you can see the rear fender. http://i85.photobucket.com/albums/k5...psa5c58c2f.jpg http://i85.photobucket.com/albums/k5...pseed4e931.jpg http://i85.photobucket.com/albums/k5...ps0f00da1c.jpg Fortunately it was at a switchback. So I had to move that tree it was wedged under and just push it down to the trail. |
So an update.
Shifting in to neutral has always been a pain. Well on the second day of our ride he couldn’t shift at all. I did put the new clutch plates in. I think I should have looked at everything when I was in there. The shifter pawl has 2 screws that hold it in place. One is missing and the other is loose. This well with the pawl flopping around it hit the clutch basket and took some small chunks out of it. I could probably reuse this, but that is not in my nature. Also these are not available either OEM or aftermarket for this old of a bike. So enter ebay. I saw several for sale, but none that I would put in. Too much geartoothing etc. I ended up finding a very good one in the UK. It’s on the way here. I still need to try to find the screw, it may have been chewed up by the tranny, but I think it could also still be in the crankcase somewhere. This will go back on with locktite. Anyway here are the carnage pictures. Shifter Pawl http://i85.photobucket.com/albums/k5...ps29wlduna.jpg http://i85.photobucket.com/albums/k5...psslshh12u.jpg Broken clutch basket http://i85.photobucket.com/albums/k5...pstc75ruge.jpg http://i85.photobucket.com/albums/k5...psgt0vpkji.jpg Pieces of clutch basket in the crankcase. http://i85.photobucket.com/albums/k5...psuaz1beqt.jpg http://i85.photobucket.com/albums/k5...psogtctasv.jpg |
Got it all back together and rode it for another top end and sold it. Was still having shifting issues and since there were no parts available I got rid of it. I trading for his current ride a 1997KLX300 (details will come later in this thread.)
Sold his RM. We had fun building it together. And he had lots of fun on it. 2 years worth. Bye bye http://i85.photobucket.com/albums/k5...psczg447vf.jpg He wanted something he could turn into a dual sport and since I have one and know all the pitfalls we decided on another KLX. So this is project number 2. This one is a 1997. It’s bone stock (Except for the pipe), dirty, leaks a little and needs some maintenance. After selling the RM and buying this I had cash for the parts. http://i85.photobucket.com/albums/k5...psvdbmbhbl.jpg http://i85.photobucket.com/albums/k5...psnnm94pi4.jpg |
It's a dual sport. I’ve been looking for a while.
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 1986 KL600. 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 not 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 an adjustable 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 build this exactly like I built the Tow Tool. I'll get it reliable and working properly then work on the performance aspect. Here it is. When I first saw it. http://i85.photobucket.com/albums/k5...20413-1144.jpg On the trailer http://i85.photobucket.com/albums/k5...cycle/KLR2.jpg In the garage. http://i85.photobucket.com/albums/k5...cycle/KLR1.jpg I need to finish the buggy in my garage before I tear into this, but I'll put a thread up when I do. |
Had major title issues but finally got it sorted.
Kinda been a pain. Moral of the story. Don't buy a "streetable" motorcycle without a title. I fired it briefly on Saturday. It runs. I'm in the putting back together stage. Swingarm bearings greased. I have a new rear shock. It's a little shorter so I have to make some tabs for it. Took care of the oil leaks. Should have my new fork seals in this week. I already have the springs. New tires. Oil, filter and plug done carb rebuilt Gas tank cleaned and coated. I plan to have it painted today. I managed to find all the plastics on ebay. Getting them all cleaned and treated. Amazingly all the light bulbs work. Including all the stuff on the cluster. :rockon: http://i85.photobucket.com/albums/k5...sassembled.jpg |
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. http://i85.photobucket.com/albums/k5...20624-1829.jpg http://youtu.be/R3DvZJzxgSQ 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. |
Pulled the motor apart to replace the clutch. Figured I'd adjust the valves and do the "doohicky" mod. That's a cam chain tensioner that is a cronic problem with these motors. Turns out the cam timing is 180 deg out. Yeesh. We'll get it straightened out though.
I also will be adjusting valves and replacing my rear tire. New trailtech Before http://i85.photobucket.com/albums/k5...cle/gauges.jpg After http://i85.photobucket.com/albums/k5...20816-1750.jpg New bars. http://i85.photobucket.com/albums/k5...ps9faba1ee.jpg Also at Hatfield McCoy I lost my plate. The bracket on the back just broke off. I didn't like it anyway so I mounted it up on the fender. I don't have a before picture but you can see it in the video of the first drive. Here is the after looks more "dirtbikey" http://i85.photobucket.com/albums/k5...psd58e3e0b.jpg http://i85.photobucket.com/albums/k5...psd84483e0.jpg So since the Trail Tech install I keep blowing fuses for the headlight and melting LED's for the neutral light. They are both on the same circuit. I hate wiring. http://i85.photobucket.com/albums/k5...pse6aa6094.jpg |
I ended up having a dead short that was blowing the LED's. Got it fixed.
Some suspension work. The front end was a little squishy. It had alot of brake dive at and would bottom on jumps. So I scarfed Chucks old bent forks that had a stiffer rate, progressive spring in them. I swapped out the springs. Took less than an hour. Also the lower forks on these are known to be a spot of flex on these heavy bikes. fortunately there are several manufacturers that make fork braces. I picked up one from Eagle Mike. http://i85.photobucket.com/albums/k5...48C652A576.jpg I have a new pipe on the way that should help with my throttle response. I am pretty amazed what a difference in jetting is required with realative small changes in intake and exhaust. Also I dropped off the tank and fairing to be painted. I can't wait to see them. |
Tank is really green.
http://i85.photobucket.com/albums/k5...6ACC97B208.jpg I'll put it on to see how it breaks up. It needs to cure over the weekend. I also got the exhaust in yesterday. http://i85.photobucket.com/albums/k5...248705F6DE.jpg The pipe portion in 33% longer so I will need to trim some side plastic. Still waiting on the fairing. http://i85.photobucket.com/albums/k5...1DEB4D41DE.jpg All together. Went for a short ride. Pipe made a huge difference. Fork brace stabilized the front end as well. http://i85.photobucket.com/albums/k5...ps33d71cb9.jpg http://i85.photobucket.com/albums/k5...pse09fe84f.jpg |
Nothing like jumping a 312lb dirt bike.
http://i85.photobucket.com/albums/k5...ps78e6b2fd.jpg So last trip I cracked my left side cover. I smacked the shifter into the case. Kinda glad I just bought and installed the MSR shifter. So I bought a new case gasket and jb welded the crack both sides. We'll see how it goes. Had to do a quick fix as we are riding this weekend at Hatfield McCoy then Friday and Saturday after Thanksgiving. I also went through it and fixed my other leaks. Oring on the oil filter, oring on the oil fill cap, seal on the clutch mechanism on the case. One final leak is on the valve cover gasket but I'm out of time tonight. I'll do that later. Been working on the front suspension. I was under the impression that the forks were pretty much identical to the 650 forks. The springs are the same, and both 38mm. However when I went to install the cartridge emulators from racetech, they don’t go down all the way. They stop about 6” from the top of the fork tube. Well turns out the 600 tubes taper to a thicker wall at the bottom triple. So the internal dimension is 29mm vs 31mm. Stronger forks than the 650. Racetech helped me out in measuring my stuff and getting me the part that would fit. The new ones are on the way. Which is good because I already drilled the holes in the dampening rods which essentially means I can’t go back. Just in case you are reading this and don’t know what an emulator does, it basically allows you to adjust your dampening and rebound independently of each other, by putting a valve in the fork. So it’s been on my stand for a couple of weeks looking like gonzo from the muppets. http://i85.photobucket.com/albums/k5...pse16140c6.jpg This has allowed me to do a couple things that I’ve been putting off. No excuses now because I can’t ride. I fixed some wiring issues. I wrapped the harness in places where it was rubbing in rubber tube. I also rerouted it to remove some pinch points. Finally I made a new hot lead and my ends were pretty bad. I also took off my stator cover again and JB welded it as I whacked it on the snow ride and it was leaking again. I need to work on some skids. |
The Fleet
The emulators worked awesome. What a huge difference being able to tune the forks. I was able to keep the front end planted. I was able to do stuff I wasn?t able to before. I?m really very pleased. I?m sure I have some fine tuning to do. I want to see how they do at peddler next weekend. I hope these cure all the bottoming.
Also I finally had to let go of the old Kawasaki bag. It was tearing pretty bad and I was afraid I?d start losing tools. I bought a Moose one and I like the quality. Comes with a rain cover. It?s a little bigger than I wanted but I can get both tubes in with a small tool kit so I?m happy. Old http://i85.photobucket.com/albums/k5...ps9cb779f4.jpg http://i85.photobucket.com/albums/k5...pseec80c47.jpg New http://i85.photobucket.com/albums/k5...ps1732214e.jpg http://i85.photobucket.com/albums/k5...psba09e248.jpg Some video of novice riding by me. This is actually a forest service road so tags etc are mandatory. https://www.youtube.com/watch?v=ylgqpVf2O6Q Same road. https://www.youtube.com/watch?v=0Czc-UTQ2fI http://i85.photobucket.com/albums/k5...e/IMG_0137.jpg http://i85.photobucket.com/albums/k5...e/IMG_0138.jpg I sold it shortly after this. I was starting to do more technical stuff and could only justify 1 bike at the time. Got a good couple of years out of it. My new KLX 300 fit the bill well. There are times I wish I had this bike back. It did many things well. I even had a chance to buy it back but 2 duals sports is overkill. And I'm sure my KLX is quicker, but doesn't have the legs to pull 70 mph all day like the 600 did. Oh well that's why I have a BMW. |
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Next installment. This is my dual sport and was my "everything" bike until I got my gasser.
Anyway I only had what I got out of my bike for a new one. So I started looking for these 3 bikes. Honda XR400, Yamaha WR400, and Kawasaki KLX300 (98-2004). The biggest downfall is all these bikes are kick start only and do not have a title from the dealership so they need converted. Lots of people do it but it takes time. And with my last title woes I just wanted to ride and go. Much to the chagrin of Gabe the XR was my last choice. Heaviest, oldest technology, worst suspension of the 3. I basically had a tie between the WR and KLX. Suspension is comperable on both. Power on the WR is way better almost 10 more HP. Which is alot on a dirtbike. KLX is the lightest by a large margin. 25lbs also a huge difference on a dirt bike. Long story short I was negotiating with 2 people yesterday. 1 - WR400 in Pittsburgh with aftermarket suspension, pipe etc. I'm pretty sure it was a ripper. No title, bill of sale only. 2 - KLX300 in Akron with aftermarket pipe, suspension. Stock motor, but a street legal title. I ended up with this one. It's missing a rear fender but I'll get that. I wanted this bike more anyway because I like Kawasaki green and always have even since I was a kid. It's got a full street legal conversion kit etc which is worth about $1200. I got the whole bike for $1200. So I throwing caution to the wind and leaving after work on Wednesday, or earlier if I can driving the 6+ hours to Akron picking up the bike then driving home. I should be back in time for work on Thursday, which will suck. http://i85.photobucket.com/albums/k5...ps159ccaed.jpg |
Mirror, LED turn signals and tail light installed. My new trail tech will be here this week.
http://i85.photobucket.com/albums/k5...ps2af4a2d0.jpg http://i85.photobucket.com/albums/k5...ps8b62334b.jpg |
I also cleaned up some wiring. The previous owner had started the dual sport kit, but just left the bulb socket and a bunch of wire on the bike. Last trip it was falling out and dangling. So that’s all gone.
Suspension done. On the list. Four Stroke Works Header Valve adjust Port and Polish head Star Wheel shifter mod Retime ACR for easier start Water pump guard Front brake line guard Radiator braces Pumper carb replace idler gear. (this is a known week part of the KLX so I'll just replace it) I’ve been remiss on some updates. All the guards and braces are on except the MSR rad guards. They are on backorder. Here are some pics. Rad brace http://i85.photobucket.com/albums/k5...psedy6jrjl.jpg http://i85.photobucket.com/albums/k5...psguh2ugvn.jpg http://i85.photobucket.com/albums/k5...psgdkds66i.jpg Front brake line guard http://i85.photobucket.com/albums/k5...psqa8jvu0m.jpg http://i85.photobucket.com/albums/k5...pshkqmcfk7.jpg Water pump guard http://i85.photobucket.com/albums/k5...psl8ls1o1t.jpg http://i85.photobucket.com/albums/k5...psvsr7rk7t.jpg Got started today. Got it torn down. The head goes to the shop tomorrow for a port and polish, and new valve seals and guides. On a surprise note when I tore it down I realized that it was not a stock so did a bunch of research and found it has a thumperracing.com 340 big bore kit. Which is awesome because I was going to spend the money and go big bore next winter. Don’t need to now. The pumper carb is a 37mm Keihin. Its borderline too big. The jetting will be a challenge. It will take some custom fitting. Also I have a fourstrokeworks header. Here it is next to the stocker. http://i85.photobucket.com/albums/k5...pslg6kwafu.jpg I’ve also had the rear shock rebuilt by a local racetech trained tech. It really needed it. So here she sits waiting for a good cleaning and reassembly. http://i85.photobucket.com/albums/k5...psktsufrke.jpg |
So a known issue with these is play in the idler gear then they hit the spur gear and crack the case. The bushing wears out. So I put a new idler on.
Play in the idler gear. http://www.youtube.com/watch?v=-jYV6...yK4Bxd420Cnn9Q New one in and ready to go. http://i85.photobucket.com/albums/k5...psdn62eop5.jpg Also they will pop out of gear occasionally. Four stroke works makes a new star shift gear for this. Old on top new on the bottom. Also comes with an aluminum spacer for more spring tension. http://i85.photobucket.com/albums/k5...psby5qunho.jpg Old http://i85.photobucket.com/albums/k5...psimr2ykpl.jpg New http://i85.photobucket.com/albums/k5...psgauhypja.jpg Got the carb in. Had to grind down the intake and put a grove in it with a file. Also had to cut out half of the top motor support. I’ll be fixing how it looks once its running and moving. It is a really tight fit. I took it to my who does all our carb tuning. I should have it back in a week or so. He lives 2 hours away and is coming up next weekend so hoping he has it with him. http://i85.photobucket.com/albums/k5...pszwi1hl1f.jpg http://i85.photobucket.com/albums/k5...pszujlwabg.jpg |
Well carb tuning seems to be going well. Fitment is tight and I’ll have to work on some bracing in there.
Started up second kick with the carb tuning based on internet research. Pretty happy. You can see in these pictures this carb sits high. Looking back I’m sure there would have been a better FCR37 to put in this but oh well this is what I have so I’ll make it work. You can see where the push cable from the throttle hits the tank and doesn’t allow it to sit down all the way. http://i85.photobucket.com/albums/k5...ps25d818b9.jpg Here you can see the nasty angle of the push as well. Throttle was not smooth at all. http://i85.photobucket.com/albums/k5...ps69eb1c93.jpg So we’re going pull cable only. Here’s what it looks like with the push cut off. He still protected the cam on it. http://i85.photobucket.com/albums/k5...ps5kac8gzo.jpg Also the cable then didn’t work right so we went with a KX500 throttle and a custom cable. The cable is being made by motion pro and should be ready in a couple of weeks. Once we’re sure it works I’ll order a spare. While I was at it I ordered a new clutch cable and a MSR Pro-raptor clutch lever assembly with the hot start lever. I needed the hot start lever and I like the adjustable clutch force on this. Should make the clutch super easy. Although we had a bit of an issue. The hot start lever hits my horn button. So for now Chuck is just getting the bike running and when it gets back to my house I’ll fix that. I have some ideas in my head on how to do it, I just need to see it to see if they’ll work. http://i85.photobucket.com/albums/k5...psp9ckijyw.jpg http://i85.photobucket.com/albums/k5...psyuhsvash.jpg So basically we’re waiting for the throttle cable and we’re done. |
Well the cable showed up Thursday. They really has us bend over though. $75 when their website says $35. Chucks been tuning the carb. Has a little to do in the midrange. Changing a jet and moving the slide one more spot. The ap shot is awesome he said. Will do power wheelies in 3rd gear!! Too speed is about 65. I may regear for a little more, but I don't want to lose top much in the bottom.
Got my new chain a sprockets on. Cruising speed is now 55. It'll go 75ish but that's not a god idea in a dry bike with unbalanced tires. I did actually get the front balanced as it was so bad. Also had to rebuild the forks. Picked up a spare rear rim to mount my other tire so based in conditions. Mud tire and dry (trials) tire. In addition I picked up a new frame with a clean title so I can register this properly as well as make some modifications. The sub frame which holds the seat, rear fender and airbox is welded on. A lot of bikes have a remove able subframe to get the carb easier. I will make this one removable. And also fix some known weak spots. And finally I have some better forks on the way. I will get more adjustment. My current forks have compression adjustments only and rebound is adjusted by oil weight. My new forks will have both compression and rebound adjustments. They will need a total rebuild and new front rim so it'll be a while yet for this. |
So an update. I’ve got about 300 miles on it.
This thing is great. Still some little things to iron out. Lets talk tuning of the FCR37. 170 main jet Needle 3rd clip from the bottom 45 pilot jet 2 turns out on the fuel screw 40 leak jet No oring yet but I might do it still. I’m undecided. There really is very little bog if any. This is hands down a great mod. I know I did a bunch of performance stuff all at the same time, so it’s hard to determine what did the most but this bike really is fast. The hot start works great. Never had a bike with a hot start. Makes starting easy. Got the front tire balanced as it was so bad. Also had to rebuild the forks due to a leaky seal. I used 7.5w 95mm from the top. I have some better forks on the way. I will get more adjustment. My current forks have compression adjustments only and rebound is adjusted by oil weight. My new forks will have both compression and rebound adjustments. They will need a total rebuild and new front rim so it'll be a while yet for this. Probably this fall. Picked up a spare rear rim to mount my other tire so based in conditions. Mud tire and dry (trials) tire. Probably get that mounted up tonight. http://i85.photobucket.com/albums/k5...pswjavulap.jpg In addition I picked up a new frame with a clean title so I can register this properly as well as make some modifications. The sub frame which holds the seat, rear fender and airbox is welded on. A lot of bikes have a remove able subframe to get the carb easier. I will make this one removable. And also fix some known weak spots. I put the bike on a shipping scale to see how much it weighed. I was hoping for 263ish. This is full of fuel. I just filled it up before I got there. http://i85.photobucket.com/albums/k5...ps5vrgycdr.jpg http://i85.photobucket.com/albums/k5...psbpp72zdn.jpg The issues I’m working on. The hot start lever hits the horn button. Plus the kill switch on this switch pack is broken. http://i85.photobucket.com/albums/k5...psyuhsvash.jpg I am working on new switches at the moment. Looks like I could get away with 4 switches on the left side. (left turn, right turn, kill, horn) Then move the head light and hi/lo beam switch to the right. This would be ideal. However I’m trying to find a solution like that and the guys at highwaydirtbikes.com have been working with me. The easy solution is to get rid of the turn signals, which I may do, not sure yet. They have some cool switches and have been helpful. The second issue is my mirrors suck. I can only see my shoulder. They don’t stick out enough. And they are cluttering up my bars. With the mounts for the mirrors there I don’t have full adjustment of my levers. So I’ll be doing some sort of custom deal here. Also I have a dyno appointment for 5/29. 1 to get hp and tq numbers and 2 to make sure the A/F ratios are good. Then get to work on my frame and forks. |
Mirrors fixed. Before I hit the dirt I can just take them off with the thumb screw and put them in my backpack or truck.
Before http://i85.photobucket.com/albums/k5...psbarlrfes.jpg http://i85.photobucket.com/albums/k5...ps7cxdawvi.jpg After http://i85.photobucket.com/albums/k5...pshj9lyrev.jpg http://i85.photobucket.com/albums/k5...psx4tbwfcc.jpg Took off my turn signals. Apparently I broke one of the back one riding again. So instead of just replacing them I ditched them. I ordered a couple of really nice switches from http://www.highwaydirtbikes.com they look really nice. So I’ll have a kill switch and horn on the left hand and the lights on/off and high beam on/off on the right hand. This will allow me to use the hot start. I also ordered a key switch as anybody can just get on my bike and kick it and go. I cleaned up the wiring to the back of the bike when I took off the signals. I’ll clean up the front with the new switches I’m putting on. Before http://i85.photobucket.com/albums/k5...psy7bbqorj.jpg After http://i85.photobucket.com/albums/k5...psgfrrczlx.jpg Finally I got my DOT trials tire mounted on my spare rim. That rim also needed a new sprocket to match and new wheel bearings. Its 2” larger than the mud tire. That will make a significant difference in RPM’s. I haven’t had a chance to ride it yet as when I get home from work it’s raining. I am happy to have the extra rim. If I get a flat riding at HMT or any place other than street riding I can just swap and go. Easy and fast. Anyway here are the pics. http://i85.photobucket.com/albums/k5...psawdmnyqa.jpg http://i85.photobucket.com/albums/k5...psdes0rcjh.jpg http://i85.photobucket.com/albums/k5...psqmeiq9ui.jpg |
Ok so I got my switches all wired up, heat shrunk and in loom. Pretty happy with the result. Also made a quick bracket for my keyswitch. I ditched the turn signals. Here are the pictures.
Before. http://i85.photobucket.com/albums/k5...pshj9lyrev.jpg http://i85.photobucket.com/albums/k5...psx4tbwfcc.jpg After Kill switch is Red, horn is black http://i85.photobucket.com/albums/k5...psblmt6mdw.jpg Red is Low Beam, black is hi beam. http://i85.photobucket.com/albums/k5...psrmwy55fo.jpg Keyswitch. The slot in the top is for the wires. I soldered it all up before I realized it comes in from the top. So I needed the slot. Not bad for 30 minutes. Function over form. http://i85.photobucket.com/albums/k5...ps0f18373a.jpg |
Well some updates. New skid plate. Moose racing.
http://i85.photobucket.com/albums/k5...psqhjftnw7.jpg Also new frame guards, works connection. Before and after. http://i85.photobucket.com/albums/k5...psgyhtkkwg.jpg http://i85.photobucket.com/albums/k5...ps7aiowlkv.jpg http://i85.photobucket.com/albums/k5...pspq7b6k9g.jpg http://i85.photobucket.com/albums/k5...ps1dhxijcu.jpg Also I was excited about my forks. I decided to not wait until fall. So I went ahead and had them valved and rebuilt by D’Orazio Dynamic Engineering Suspension Services, https://www.facebook.com/DDESuspension. He’s done a couple shocks for me as well. Apparently ’94 KX forks are considered vintage. I had a hard time finding springs for the right weight for them. I stumbled on Cannon Race Craft. http://www.Cannonracecraft.com. They custom make springs at very reasonable prices. I was very surprised to see the price. Well worth the phone call. They also were great to deal with and told me my springs would be custom wound to my exact specs and delivered in 3 – 4 weeks. Turns out they were way off. I had them in my hands in 2. Great customer service. Also got a Galfer brake line. Out with the old. http://i85.photobucket.com/albums/k5...pses7hdq6r.jpg Old forks sitting next to new forks. http://i85.photobucket.com/albums/k5...psxbug7v34.jpg Installed including UFO fork guards. http://i85.photobucket.com/albums/k5...psykam8ysy.jpg She’s ready for our HMT ride in a couple weeks. I’ll be hitting some local stuff here in the next couple of days hopefully getting some video. |
So I absolutely love the suspension on this thing. Very balanced.
I had custom retro 90’s graphics made. I really like the way they turned out. I’ll post pics when they are ready to be put on. But Kawasaki for some strange reason primes and paints their aluminum swingarms. So all the scratches come out as black (primer color) I didn’t want to put new graphics on a painted, scratched swingarm. So it’s off and ready to be stripped. Plus this will keep me from riding it before my knee is ready. http://i85.photobucket.com/albums/k5...pssyfg5sqb.jpg http://i85.photobucket.com/albums/k5...ps1dgtfpzf.jpg We’re using this I thought it ironic that it’s “Aircraft Paint Remover” but the rear of the can says “Do Not Use On Aircraft” http://i85.photobucket.com/albums/k5...ps3dgzwx3q.jpg http://i85.photobucket.com/albums/k5...ps83ohnilo.jpg |
Quick update. I'll go into detail later but love the look. Shiny swingarm and retro 90's graphics
http://i85.photobucket.com/albums/k5...pshxdttkv5.jpg Shrouds. http://i85.photobucket.com/albums/k5...ps9wi2fios.jpg I have some more on order so no overall pics yet. |
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