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Old 03-28-2013, 03:50 PM   #31
DirtReeper
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You gonna let us ride at Moab Hondo?
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Quoth the Darth Peach: "Must work to afford Bikethings"
Quoth Dorzok, it's a BMW. just activate the levitation function that's part of the optional accessory outer space adventure package.
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Old 03-28-2013, 08:18 PM   #32
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Quote:
Originally Posted by DirtReeper View Post
You gonna let us ride at Moab Hondo?
I'mk just hoping that I will be able to make Moab this year!
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Old 05-11-2013, 07:49 AM   #33
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Baja Designs Stator Rewind

When I was testing the electrical system for a 12vdc LED headlight replacement, I found that the stock KLX450R stator was not capable of maintaing a minimum 12v at the battery with the LED headlight on.

So I sent the stock stator to Baja Designs and had them rewind the stator HERE.



I also ordered their regulator/rectifier HERE-



Side cover removed along with the stator-



The BD Regulator / rectifier fit in the stock location- -



I am happy to say that with the LED headlight on High and both cooling fans running, the stator has no problem keeping up with electrical demand.

I'll be adding hard wiring for a Montana 600 GPS this week & don't anticipate any issues -
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Old 05-11-2013, 08:09 AM   #34
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LED Headlight Upgrade

To say that the stock 35 watt, AC powered headlight on the KLX450R is lacking is a huge understatement.

Once the bike is plated the stock headlight is no more that a headlight in the legal sense and has no practical output at night.

So I decided to upgrade the stock headlight mask with an LED light that I bought from the Vendors section, ADV Monster-

http://advrider.com/forums/showthread.php?t=821159

Light specs -
  • Wide Beam
  • 3600 lumens
  • Cree XM-L T6 LEDs
  • 2.4 amps (28 watts) @12v
  • aluminum housing
  • Length: 70mm , Diameter 55mm
  • Black durable coating
  • o-ring sealed housing
  • one meter wire lead
  • includes flat mount mounting option - (stainless)
  • shatter resistant lens


I bought the light, variable output controller, and light holder (to be fitted to my own mask mount).

After analyzing the electrical system on the KLX450R, I found a switched 12v circuit that I would use to control the headlight through a 12v relay. That way the headlight would only run when the engine was running.

I would control the headlight by using a headlight switch that I bought from Paul at Highway Dirt Bikes - http://www.highwaydirtbikes.com/HDB_...w736d3j8c05cf2



I did have to move the electrical wiring inside the switch in order for it to properly control the Variable light controller from ADV Monster-



The ADV Monster light controller has one output that is switched between full 12 volts and the variable output. The controller allows you to use the full 12v as high beam and the the reduced setting as low beam. The controller uses a seperate 12v line to know when to go to full 12v, and the High position of the switch provides that.

Here is the stock headlight mask with the stock bulb-



With the light bulb removed I found that the Model 60 LED light from ADV Monster would be a good fit in the mask-



So I opened up the mask with a hot knife -



Then I needed to create a flat plate that I could mount the light to. Cardboard first-



Then I made a hole for the LED Model 60-



I mounted the light bracket from ADV Monster to the plate & checked the assemble for fit-





I then used some "Great Stuff" expanding foam to attach the mount to the mask- weighted it down with some big sockets. I did this in small stages so that I did not get any foam on the Model 60 light itself- I wanted to be able to remove it if necessary-



After the foam was dry I trimmed off the excess and then drilled 4 ventilation holes through the foam & the mask - you can see the holes in the 4 corners of the reflector-



Here it is mounted on the KLX450R-



In test rides I have found the light to be a huge improvement over stock, and more than adequate for street or trail riding.
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Old 05-11-2013, 08:33 AM   #35
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Hammerhead Designs Shifter Upgrade

I found that the stock shifter was too short for me when wearing my Sidi Crossfire boots, so I ordered a Hammerhead Designs extended shifter for the KX450 -

http://www.hdmoto.com/ProductDetails...tCode=KXF450SL

I ordered the 15 mm longer shifter-



Installed on the bike-





On the trail I found that it was much easier to control my shifting- well worth the expense!
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Old 05-11-2013, 08:57 AM   #36
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Highway Dirt Bikes Handguards & Striker Mount

I wanted to have the best designed, strongest handguard system available and luckily for me, Highway Dirt Bikes is right up the road from me in Denver.

The great thing about their handguards is the top clamp. Unlike many systems whose inside attachment point is the handlebar itself, HDB uses it's unique top clamp that attaches to the handlebar mount, creating a super strong attachment point.

After I discussed the top clamp configuration with Paul, I also decided to use his TailTech Striker Mount with the guards & top clamp.

I decided to wire in a keyed ignition & electrical switch, LED turn light indicators, LED Low & High Beam indicators, and 2 switch positions- one for the fan cooling system & one reserved -



When I bought my guards I chose to use the antivibration threaded handlebar inserts with the new Pro Taper CR High handlebar.

HDB supplies the insert, tap & alignment collar-



Here I'm tapping the bar end using the supplied tap & alignment collar-



Tapped & insert installed-





When installed, the guards are super strong- no pulling out of the bar!

Here's a pic of one of the 12v Headlight beam indicator LEDs I used in the top clamp. I toned it down a bit with some black paint-



Here's a shot of a set of 3/4 inch tall bar risers that I also got from HDB- this gives me an easier reach when standing and supplies better clearance between the Scotts Damper and the LED wiring-



Completed shots-



In this shot you can see the HDB Perch Switches on the right side of the bar that are used as Start & Stop switches and the Fold Out, Hideaway Mirrors-

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Hondo screwed with this post 05-14-2013 at 08:58 AM
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Old 05-13-2013, 08:18 AM   #37
singleslammer
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Cool stuff man. Thanks for pointing out that LED head lights. I wasn't aware that there was an option that inexpensive. I have already ordered one of their three bulb units.
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Old 05-13-2013, 08:48 AM   #38
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Quote:
Originally Posted by singleslammer View Post
Cool stuff man. Thanks for pointing out that LED head lights. I wasn't aware that there was an option that inexpensive. I have already ordered one of their three bulb units.
I found out that the stock KLX450R electrical system output for the stock headlight was AC, so the stator upgrade & LED headlight really should go together.

I did try the LED headlight with a direct battery connection but stock
stator output was still too low to adequately charge the battery.
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Old 05-13-2013, 08:59 AM   #39
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I am actually trying out a few options (everything from Harbor Freight lights to Clearwater LEDs) for a new product that my company is coming out with soon. If these are as good as people say on here, this will be an excellent option for our system. One of my partners rides an XR650R Honda that has the same issues with the Stator and AC power. It sucks that the lights that might run on such a low output system (like the XR and the KLX) are ruled out due to being DC only.
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Old 05-15-2013, 04:39 PM   #40
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Suspension update-

I just checked the sag of the rear suspension and found that the spring that is installed is woefully preloaded for my 210 lbs + riding gear & tools.

So after talking with the the folks at Racetech, I ordered a spring for the shock & will be documenting the upgrade soon.
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Old 05-19-2013, 03:46 PM   #41
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Today I hard wired the Garmin Montana cradle into the bike & mounted the Ram mount -

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Old 05-23-2013, 05:42 AM   #42
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Hadlebar & Grips

I just realized that I forgot to include info on the new handlebar & grips that I installed-

Protaper Contour Fat Bar, CR High Bend -




with Protaper Pillow Top Lite Grips -

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Old 05-29-2013, 08:19 AM   #43
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Rear Spring Upgrade

The KLX450R comes from the factory with a shock spring that is designed for a rider of about 170lbs, and as I'm 200+lbs, I needed to upgrade my spring.

So I went to Racetech and ran their spring calculator for me & my bike. I figured my weight wearing full gear, Wolfman Day Tripper Saddle Bags containing tubes & tools, and the extra fuel that the 4 gallon Acerbis tank provides.

In order to remove the shock for the spring change, you can either lower the subframe or drop the swingarm - I chose to drop the swingarm. The exhaust also needs to be removed & the lower linkage separated-



Here is the shock with old spring installed & the new one standing by-



I took my new spring & shock to Tfog Wheelsports in Golden, Colorado & ADV member Tfogger swapped out the spring in about 5 minutes for a small fee- Thanks Jim!

Here's the shock ready to be installed-



Now I just have to set the sag & I'm ready to go-
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Hondo screwed with this post 07-18-2013 at 10:30 AM
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Old 05-29-2013, 09:18 AM   #44
D-Train
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Looking good Hondo Bet you wish you had this thing on a few of the off road stretches of the Dino ride...
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Old 05-29-2013, 09:29 AM   #45
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Quote:
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Looking good Hondo Bet you wish you had this thing on a few of the off road stretches of the Dino ride...
Next year my friend!
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