jshump
Pack Dog
Update on my KLR 600 rebuild.
So last year I got a KLR 600 in fairly good nic for next to nothing, by around October I decided it would be a good idea to nail the doohickey (a common fault in all KLR's), and that's where it all began....
The doohickey led to the discovery of a stretched balancer chain = new chain, new guides = long wait for Kawa to get the part in
so that led to "maybe I should fix up some other bits n bobs whilst I wait" = remove subframe to get a crack welded
that led to "stuff it, lets go the whole hog" = completely stripped bike, down to component level, plenty parts powder coated. Engine resprayed. Carb modded. T-mod. New sus parts. New bearings. Lots of new bolts. and various other assorted upgrades.
So it's drawing to close now and as I wait for some final parts to arrive I though I would share the progress so far.
This was the original issue, stuffed doohickey (it's a 1988 model so I was surprised that it wasn't more mangled).
<img src="https://farm3.static.flickr.com/2750/4382467790_8436d10c4a.jpg" alt="" border="0" />
This is where the stretched cam chain actually started to each the crankcase.
<img src="https://farm5.static.flickr.com/4059/4381708879_102f141117.jpg" alt="" border="0" />
The bike in various stages of stripping
<img src="https://farm3.static.flickr.com/2750/4381710273_6ea349ce13.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2800/4382471136_236a1fba53.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4006/4381715049_39fc278a6e.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2582/4123769891_e256ffe2c7.jpg" alt="" border="0" />
Rebuild pics
<img src="https://farm3.static.flickr.com/2718/4382472568_17b008ab7d.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2778/4381714463_46c95980c7.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2764/4381729549_df10d8223a.jpg" alt="" border="0" />
Parts ready for powder coating
<img src="https://farm5.static.flickr.com/4007/4382478212_c93f03d890.jpg" alt="" border="0" />
The masking tape on the subframe was where it was cracked. The rust on the spokes was so bad I used an
angle grinder to cut them off and ordered new ss ones.
<img src="https://farm3.static.flickr.com/2794/4382478782_57661b434c.jpg" alt="" border="0" />
My makeshift 'safety' pulley.
<img src="https://farm3.static.flickr.com/2773/4381719451_8f18cdb36b.jpg" alt="" border="0" />
bolted into the wall ;D
<img src="https://farm5.static.flickr.com/4048/4382479860_dd23c70fcb.jpg" alt="" border="0" />
Redoing various parts:
I have pretty much redone every part I have put back. Strip, clean, lube, protect, paint.
The indicator housing before:
<img src="https://farm5.static.flickr.com/4044/4381721215_369fc7281b.jpg" alt="" border="0" />
after:
<img src="https://farm5.static.flickr.com/4029/4382481632_f7bc06c2fb.jpg" alt="" border="0" />
Brake assembly before:
<img src="https://farm3.static.flickr.com/2730/4381723277_96e4ebb100.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4007/4381723867_147a080c2c.jpg" alt="" border="0" />
after:
Unfortunately my camera decided it liked my beer more.
<img src="https://farm5.static.flickr.com/4005/4382484350_531f3d64ba.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4064/4381725241_9da6935bb2.jpg" alt="" border="0" />
Some of the corrosion on the bolts.
The swing-arm linkage bolt had to be smacked out so hard I compressed the threads and had to have them re-cut.
<img src="https://farm3.static.flickr.com/2740/4382485642_a4ba3a4744.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2694/4381726821_82d5df8123.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2698/4382487094_ea61777459.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2727/4382487746_73ca4d8432.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2719/4382488436_e0d8cf57ec.jpg" alt="" border="0" />
The swing-arm before and after.
It's still a KLR so I made my own chain guard.
<img src="https://farm5.static.flickr.com/4045/4382490826_2ddbf687ea.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4014/4382491530_57da77b2c6.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4048/4381732665_474d5c6519.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2794/4381733427_607fe95309.jpg" alt="" border="0" />
Some final shots of the rear before and after
<img src="https://farm3.static.flickr.com/2761/4382494284_795448e9dd.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4045/4382494856_90953b004f.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2713/4382495546_7c0b76cc20.jpg" alt="" border="0" />
The headset's new look. Had to chuck a new bearing in.
<img src="https://farm3.static.flickr.com/2705/4381737567_91565aac12.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2778/4382497668_000f23e6ba.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4028/4381738951_6e3894b6db.jpg" alt="" border="0" />
So am still waiting for front fender, bushes for the front shocks, HID light kit. Once that's here I can get my baby back on the road and get the plastics sorted. Can't wait!
So last year I got a KLR 600 in fairly good nic for next to nothing, by around October I decided it would be a good idea to nail the doohickey (a common fault in all KLR's), and that's where it all began....
The doohickey led to the discovery of a stretched balancer chain = new chain, new guides = long wait for Kawa to get the part in
so that led to "maybe I should fix up some other bits n bobs whilst I wait" = remove subframe to get a crack welded
that led to "stuff it, lets go the whole hog" = completely stripped bike, down to component level, plenty parts powder coated. Engine resprayed. Carb modded. T-mod. New sus parts. New bearings. Lots of new bolts. and various other assorted upgrades.
So it's drawing to close now and as I wait for some final parts to arrive I though I would share the progress so far.
This was the original issue, stuffed doohickey (it's a 1988 model so I was surprised that it wasn't more mangled).
<img src="https://farm3.static.flickr.com/2750/4382467790_8436d10c4a.jpg" alt="" border="0" />
This is where the stretched cam chain actually started to each the crankcase.
<img src="https://farm5.static.flickr.com/4059/4381708879_102f141117.jpg" alt="" border="0" />
The bike in various stages of stripping
<img src="https://farm3.static.flickr.com/2750/4381710273_6ea349ce13.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2800/4382471136_236a1fba53.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4006/4381715049_39fc278a6e.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2582/4123769891_e256ffe2c7.jpg" alt="" border="0" />
Rebuild pics
<img src="https://farm3.static.flickr.com/2718/4382472568_17b008ab7d.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2778/4381714463_46c95980c7.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2764/4381729549_df10d8223a.jpg" alt="" border="0" />
Parts ready for powder coating
<img src="https://farm5.static.flickr.com/4007/4382478212_c93f03d890.jpg" alt="" border="0" />
The masking tape on the subframe was where it was cracked. The rust on the spokes was so bad I used an
angle grinder to cut them off and ordered new ss ones.
<img src="https://farm3.static.flickr.com/2794/4382478782_57661b434c.jpg" alt="" border="0" />
My makeshift 'safety' pulley.
<img src="https://farm3.static.flickr.com/2773/4381719451_8f18cdb36b.jpg" alt="" border="0" />
bolted into the wall ;D
<img src="https://farm5.static.flickr.com/4048/4382479860_dd23c70fcb.jpg" alt="" border="0" />
Redoing various parts:
I have pretty much redone every part I have put back. Strip, clean, lube, protect, paint.
The indicator housing before:
<img src="https://farm5.static.flickr.com/4044/4381721215_369fc7281b.jpg" alt="" border="0" />
after:
<img src="https://farm5.static.flickr.com/4029/4382481632_f7bc06c2fb.jpg" alt="" border="0" />
Brake assembly before:
<img src="https://farm3.static.flickr.com/2730/4381723277_96e4ebb100.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4007/4381723867_147a080c2c.jpg" alt="" border="0" />
after:
Unfortunately my camera decided it liked my beer more.
<img src="https://farm5.static.flickr.com/4005/4382484350_531f3d64ba.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4064/4381725241_9da6935bb2.jpg" alt="" border="0" />
Some of the corrosion on the bolts.
The swing-arm linkage bolt had to be smacked out so hard I compressed the threads and had to have them re-cut.
<img src="https://farm3.static.flickr.com/2740/4382485642_a4ba3a4744.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2694/4381726821_82d5df8123.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2698/4382487094_ea61777459.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2727/4382487746_73ca4d8432.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2719/4382488436_e0d8cf57ec.jpg" alt="" border="0" />
The swing-arm before and after.
It's still a KLR so I made my own chain guard.
<img src="https://farm5.static.flickr.com/4045/4382490826_2ddbf687ea.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4014/4382491530_57da77b2c6.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4048/4381732665_474d5c6519.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2794/4381733427_607fe95309.jpg" alt="" border="0" />
Some final shots of the rear before and after
<img src="https://farm3.static.flickr.com/2761/4382494284_795448e9dd.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4045/4382494856_90953b004f.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2713/4382495546_7c0b76cc20.jpg" alt="" border="0" />
The headset's new look. Had to chuck a new bearing in.
<img src="https://farm3.static.flickr.com/2705/4381737567_91565aac12.jpg" alt="" border="0" />
<img src="https://farm3.static.flickr.com/2778/4382497668_000f23e6ba.jpg" alt="" border="0" />
<img src="https://farm5.static.flickr.com/4028/4381738951_6e3894b6db.jpg" alt="" border="0" />
So am still waiting for front fender, bushes for the front shocks, HID light kit. Once that's here I can get my baby back on the road and get the plastics sorted. Can't wait!
