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Old 04-01-2008, 11:05 PM   #1
BDKW1 OP
KL"X" not "R"
 
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KLR rear shock sacrilege

Well, after a nice long off-road trip to the San Felipe 250 I have come to a couple of conclusions on My KLR650. The front fork swap was totally worth it and I need to get My arse moving on the rear suspension. Actually, it needs to move without My arse moving, but whatever.......

I want this thing to ride like a 73 Caddy Fleetwood on the street and still be able to hit the whoops like My KLX 300.

So, to that end I got a White Power PDS shock from a KTM for a transplant.

Wussy stock shock, meet your replacement!



Wait, the reservoirs in the wrong spot? Hold on a second, there, this should fix that......



More later..........


P.S. I'm just using this shock to watch the KTM guys twitch
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Old 04-02-2008, 06:28 AM   #2
climberevan
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excellent work, amigo!

NICE! i can't wait to see what you do next.... i've kinda gone over to the dark side--i bought a GS. i know, i know.... but man, it rides like a dream and 90hp is sure fun. i'm not sure if i'll keep the KLR or not: getting around the country with 3 bikes and 2 cages is pretty complicated.

are you thinking of getting into the engine? i believe Eagle Mike claims 10+ additional HP from the 705 kit and big pipe. that would be enough to make the KLR move quite a bit better.

evan
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Old 04-02-2008, 08:43 AM   #3
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Quote:
Originally Posted by climberevan
are you thinking of getting into the engine? i believe Eagle Mike claims 10+ additional HP from the 705 kit and big pipe. that would be enough to make the KLR move quite a bit better.

evan

Coming from a KLX300, power is not the problem. As long as the engine is running, I have no plans to tear into it.


I'll show you the darkside! Just for that I'm going to find a Beemmeer part and frankenstien it on to the KLR.
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Old 04-02-2008, 01:25 PM   #4
greengoose
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done in Classic KLR fashion
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Old 04-02-2008, 01:31 PM   #5
Hondo
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Old 04-05-2008, 07:52 PM   #6
BDKW1 OP
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Quote:
Originally Posted by greengoose
done in Classic KLR fashion
Oh, you ain't seen nuttin yet

OK, first off, the new links..... I made these about .625 longer to slow down the motion ratio a little for more travel, but it also yields a little better curve.... I was going to make the center cut-out say FYYFF, but it would have cost more



Next was re-clocking the compression adjuster to clear the frame. It also got a AN weld on fitting for the remote reservoir. The AN fitting cost more, but it was worth it........





Since the inconsiderate WP engineers didn't make the bottom of the shock long enough, the bottom needed to be extended a little to keep the larger OD spring from fouling the swing-arm Lucky I had a donor shock laying around


The longer links also helped with this...
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Old 04-05-2008, 09:54 PM   #7
lvdukerider
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Way back in 1992 When I blew the stock shock out of my 1990 KLR650 I ordered up a White Power replacement shock for about $500. It diddent have the remote resevour, but worked great just the same.
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Old 04-05-2008, 10:32 PM   #8
Zerodog
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Holy Crap!! That is a lot of work to get that sucker on there. Let me know if you need some ideas for the guts on that thing. It might be a big improvement on the KLR. One thing to consider is the PDS system in the shock. It is made for a bike with no linkage so it gets its progression internally. With the linkage on the Kawi it will need to run a pretty soft secondary piston to not hit a wall of damping and mechanical progression as it gets deep in the stroke.
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Old 04-05-2008, 11:03 PM   #9
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Quote:
Originally Posted by Zerodog
With the linkage on the Kawi it will need to run a pretty soft secondary piston to not hit a wall of damping and mechanical progression as it gets deep in the stroke.
Do you know how much a KLR wieghs? I don't think I'm going to have to much damping. But yeah, I've got a bag full of shims (not the shemale kind) if I need to.
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Old 04-06-2008, 06:28 AM   #10
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Old 04-06-2008, 01:15 PM   #11
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Something seems to be missing..... Besides My common sense......



I'll teach that tube to get in My way!

As I was grinding down the welds on the frame from the cross tube I thought to Myself " Self, this would be a lot easier with the motor out"

Which brought up the next thought " How the fuck did a simple shock swap turn into Me contemplating pulling the motor?"
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Old 04-06-2008, 04:04 PM   #12
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Oh look, some chromoly jumped off the material rack and on to My bike!



Thats about it for today.
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Old 04-07-2008, 04:57 AM   #13
thecanoeguy
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oh dear

now we are getting serious ,it looks like a no turning back stage in the old jobbie here ,this should be interesting ,maybe your next project should be whacking a klr donk into an 04 640 adventure ,that i would like to see
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Old 04-07-2008, 05:51 AM   #14
Fubars
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Fubars screwed with this post 04-07-2008 at 12:18 PM
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Old 04-07-2008, 06:00 AM   #15
Nanuq
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