Essentials for KLR ADV bike

[dutchjohn]

I found the stuff at happy trails how much ?oh hell its been over the years but I think I have 1500 to 2000
in all my junk pot pans kitchen sink and all

Ducthjohn

[farkleknocker]

So I can suck at least $1k out of most people...

Just getting the bike cleaned up and painted now. I can't display my creations on a carcass. I will update as I go and let you guys be part of the creation process. Strength in numbers and great minds think alike.

[hippiebrian]

Looking at mine I keep thinking "all that dash and no locking glove box...". Heck, my people 150 scooter has a glove box, can't my KLR?

[Unstable Rider]

Originally Posted by hippiebrian

Looking at mine I keep thinking "all that dash and no locking glove box...". Heck, my people 150 scooter has a glove box, can't my KLR?

= Pelican cases.

~mission accomplished.

[farkleknocker]

Here's what I have so far. I made a copy of the stock skid plate, then widened it 1.5" on the brake side and 2" on the shifter side. I then made a copy of each side and moved them forward about 5.5", then filled in the middle making sure the tire won't hit at full compression.

I still have a ton of shaping left and now is a good time to make any aesthetic changes. The amount of storage it provides is pretty huge, 14" at it's widest inside point. It will fit a 12" pair of tire irons along with any other tools you could possibly want to carry. After this shape is completed and the final part is made it will be the outside shell. Then I have to build the inside. After the inside is done it will be bolted and epoxied as the inner part will support the entire unit where it bolts to the downtube. After that's done I have to make the lid for it. yay. The lid will be secured with probably 4 Dzus 1/4 turn D-ring fasteners. I will probably make small stainless lanyards for them and the lid in case they want to work their way out on the trail.

I talked to some guys and they recommend a full kevlar outer layer backed by carbon. Don't worry, they make kevlar in black too, along with all kinds of other colors and it looks SICK compared to carbon IMO. Really trippy looking.

Keep in mind it may look out of place on a pre-08, like a tumor. No worse than that eyesore of a toolbox Touratech makes. But it will be integrated into the rest of the bodywork I have planned. I also made it over sized in height so I can cut it down to the final desired shape after produced.

Whatya think so far?

[Spot Me 2]

I'm liking what I'm seeing so far. I have wondered for years why no one has done this. Its only been Kawi's best selling bike for about 25 yrs now.....

[SCQTT]

Originally Posted by Spot Me 2

Its only been Kawi's best selling bike for about 25 yrs now.....

Yeah....no.


Pull this out of your butt?

They were only selling about 500 a year back in the late 80s when the bike was new. peak was in the mid- 2000's with just over 5,000 pieces.

The KLR has never been Kawasaki's best selling bike.

It has been a long term success becuase they have been able to amortize their R&D (lol) & tooling costs over a very long period of time.




FK your skidplate looks like a bigger stock Tengai bottom fairing.

[GMJinARK]

Dutchjohn, It looks like your KLR is pretty well outfitted. Can you share some details about what you've added to it? I'm new to the dual sport arena, and I'm trying to get my '09 setup right. Thanks.

[NCK]

Very interesting skidplate. Can you give some bullet points on the point of it? For example:
- Extra storage (how many liters?)
- Good protection (strong as alumn equivalents)
- low weight, etc...

[farkleknocker]

Those are the points. lol

This is the beginning of my attempt to bring back the Tengai per se, and develop a truly bulletproof body and accessories for the KLR. Everyone, almost, loves the look of the Dakar bikes. I love the KTM Rally 450 myself but it's $50k. I want to be able to buy a new KLR and bolt on a kit that looks like it with more functionality than what's available. The KLR is the best bike in it's class and perfect for my quest.

Storage wise it will hold all tooling and heavy parts. I don't know the final cu. capacity yet as I still have to build the inner piece. Bringing all the tools and heavy parts down below the top of the engine will lower the CG. If you look at the old skidplate inside of the new one you can get an idea what space will be available.

I will spare no expense with materials cost. It will be as strong as I want it, which is strong enough to withstand a sledgehammer repeatedly. I will increase thickness until I can drive my Rover across it and not crack it. The bike I am building it on does not run currently so I have to think of different ways to test it. Stronger than any steel or aluminum skid plate on the market, that about sums it up. I will perform whatever test anyone comes up with that I am capable of and then pass it on to anyone else that wants to test it. Then after everyone agrees it's bulletproof we can go into production.

I can then, very easily modify and adapt the outside skin of the plate to any other bike and I just have to make a new inner layer and cover.

This is the skid plate inspiration.

[NCK]

Originally Posted by farkleknocker

Those are the points. lol

This is the beginning of my attempt to bring back the Tengai per se, and develop a truly bulletproof body and accessories for the KLR. Everyone, almost, loves the look of the Dakar bikes. I love the KTM Rally 450 myself but it's $50k. I want to be able to buy a new KLR and bolt on a kit that looks like it with more functionality than what's available. The KLR is the best bike in it's class and perfect for my quest.

Storage wise it will hold all tooling and heavy parts. I don't know the final cu. capacity yet as I still have to build the inner piece. Bringing all the tools and heavy parts down below the top of the engine will lower the CG. If you look at the old skidplate inside of the new one you can get an idea what space will be available.

I will spare no expense with materials cost. It will be as strong as I want it, which is strong enough to withstand a sledgehammer repeatedly. I will increase thickness until I can drive my Rover across it and not crack it. The bike I am building it on does not run currently so I have to think of different ways to test it. Stronger than any steel or aluminum skid plate on the market, that about sums it up. I will perform whatever test anyone comes up with that I am capable of and then pass it on to anyone else that wants to test it. Then after everyone agrees it's bulletproof we can go into production.

I can then, very easily modify and adapt the outside skin of the plate to any other bike and I just have to make a new inner layer and cover.

This is the skid plate inspiration.

Helpful x1000.

This is a awesome endeavor. Might I suggest you make sure this works with the new IMS 10 Gallon tanks? I wouldn't have a KLR without one.

[el queso]

Originally Posted by farkleknocker

What are some things you would like to see available for the KLR that aren't available now?

Horsepower...

Seems to me like the only thing not currently available is updated bodywork for the 07 and earlier bikes and slimmer bodywork for the 08+ bikes; something along the lines of your rally raid inspiration. A left sidecover that incorporates tool storage (eliminates emmisions equipment) would be cool too.

Pete

[NCK]

Rear and Front disc brake gaurds. Availible for the old generation bikes, nobody has begun making them for the new generation. Make these, you'll sell a ton of them.

[farkleknocker]

It does look like it will fit with the 10 gallon no problem. Can someone tell me if the pre-08 and 08+ skidplates bolt on the same? One bolt on downtube, 2 under the engine on the insides of the frame rails...

What I need to do is get this one finished along with some other small pieces I will be making so I can sell some and afford to get an 08+ and work on them side by side, that way I know everything fits.

Disc guards for 08+ I can do. I think I will make them separate from the low front fender/brace combo, that way everyone can bolt them on. Probably won't be bolt on, more like bolts and zip ties like the old plastic ones made. But I don't have an 08 to model on yet.

I also plan next to do a rear brake line piece that puts the line on top of the swingarm not dangling around on the side. One of the worst designs I have seen in a dirt bike.

I have the skid about 90% finished and almost ready to make a mold. After that I have my working piece to start making the inside.

[farkleknocker]

I found this pic. Are these the factory mounts on the 08+? If so, they will be in the way of all the storage space. I still see a tab on the frame though. The pre 08's don't have those tabs coming off the engine mounts. They could be cut off or use pre-08 engine mounts.