$5,999
New Haven, Connecticut
Category
-
Engine
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Posted Over 1 Month
See my other listings for a similarly specced sister bike.A 2002 Kawasaki KLR 650 modified for a transcontinental trip. The bike was overhauled from the ground up by a master engineer and industrial designer spending in excess of 500 hours in designing, manufacturing and testing. Due to owner's personal circumstances the bike never went on the trip it was intended for but it's ready to go anywhere, anytime; awaiting its new owner's aspirations. The bike has approximately 13.7K miles and has been used for 1K miles since its overhaul.The KLR is a known work mule; it is the preferred mode of transport by the US Marine Corps and numerous police forces around the world. Over the course of its 25+ ongoing years of production, Kawasaki has not made any major changes to the proven design, keeping the KLRs easily fixable, parts low cost and readily available. The foreseen challenges of a transcontinental trip meant the original bike needed to be improved. Hundreds of hours of research and design considerations were put into the bike to fit the stringent requirements for sturdiness, comfort, reliability and safety. Sturdiness: The motorcycle needed to carry 450lbs of rider and luggage on a regular basis, well above the 350lbs specced by Kawasaki. Brakes, frame and suspension had to be strengthened. Oversized and slotted 12.6 inch floating brake rotor, and steel braided lines front and rear provide tremendous stopping power without fade or pulsation. Frame assembly is strengthened by upgrading to 12.9 class bolts in all load bearing locations. In order to support the increased weight, suspension is beefed up with an 8.0kg spring. Comfort: The motorcycle needed to be comfortable across thousands of miles of paved, unpaved, gravel and off-road conditions. Comfortable seating, vibration reduction, accessory power outlets, heated grips, wind protection and ergonomic improvements were integrated into the new design. The upgraded Sargent brand seat makes long hours on the saddle a breeze while reducing vibration and the weave pattern texture helps with circulation. Alloy handlebar with bar-end weights, silicone hand grips cut down the engine vibrations. Isolated rear view mirrors enhance safety and visibility. Oversized windshield and hand reflectors together with heated grips ensure that the rider is protected from whatever nature may bring. Upgraded lighting system resulted in plenty of extra electrical power, so 12V and 5V DC electrical outlets were added under the seat and in the top case for running accessories (like heated vest) and USB devices as well as quick hook up locations for charging and jumping. Reliability:The motorcycle needed to be reliable in all environmental conditions over a terrain that varied from mountain ranges to tropical forests to desert-like conditions. For maximum reliability original parts were replaced for complete waterproofing, adjustability, and better oil/fuel/air filtering. FAG HRS series sealed wheel bearings and all terrain x-ring chain ensure a maintenance-free drivetrain through rain, mud or sand. Carburetor intake is lifted above the airbox via a snorkel for confident river crossings. Oil system is fitted with a user cleanable oil filter and a magnet drain screw so there is no need to change an oil filter, ever. Fuel system is fitted with an in-line fuel filter to keep the engine running smoothly regardless of the quality of the fuel. Electrical system is upgraded to marine grade cables and connectors where applicable and everything is sealed to IP-67 standards for full water-proofing. Carburetor is fitted with an extended fuel adjustment screw so that fuel/air ratio adjustments can be made on the go. A mains cut-off switch ensures that no peripherals are left lugging down the electrical system. Safety: Enhance safety features were added for engine protection, increased visibility, quick maintenance, and easy access to consumables. Piercing bright and pulsating LED brake lights command attention from other drivers on the road. Engine crash bars protect the rider's legs and vitals in the event of a topple-over. Alloy skid plate under the engine make sure the oil and water circuitry underneath the engine is well protected from rocks and debris. Load bearing bolts that are subject to vibrations and eventual loosening are torqued to manufacturer specifications, secured in place with removable threadlocker and visually marked for quick daily inspection. Center stand with support arm makes oil changes and tire repairs a breeze. What this bike is not: This bike was not modified for looks or speed, you will not find trick suspension, carbon fiber muffler or show floor LED lights. Everything is there for a purpose or has been taken out because it did not fit the build. ------------Here is a list of all upgrades totaling close to $4000 in parts alone: Body and luggage:ProTaper ATV HI Seven Eighths Platinum Handlebars Barkbusters aluminium handguard with bar end weights Barkbusters VPS plastic guard and wind deflector ProTaper ATV pillow top vibration reducing grips Sargent Adventure Touring Seat for KLR650: 2" lowering blocks for pegs made from tool steel installed with 40mm 10.9 grade steel alloy bolts: SW-MOTECH Crashbars/Engine Guards Kawasaki KLR650A: Happy Trails Dash Panel Kawasaki KLR650A '87-'07: Happy Trails SU Side Rack Kawasaki KLR650: Pelican 1500 black top case: Pelican 1550 silver side case (one side only - not pictured): Happy-Trails Pannier Mount Kit Original Style Happy Trails Centerstand Kawasaki KLR650: Clearview shields 16" touring shield for KLR650: TPI mirror vibration dampers PO2000: Wolfman Explorer Tank Bag (not pictured):Happy Trail KLR650 Black Skid Plate (not pictured)Brakes: EBC Oversize SuperMoto 320mm Disc Brake Conversion Kits for KAWASAKI KLR650: Russell braided Stainless Steel brake lines front: Galfer braided Stainless Steel brake lines rear: MASTERGUARD REAR MASTER brake CYLINDER GUARD: Engine and fuel:Extended Fuel Mixture Screw KLR650 '84-'Current procycle for keihn carburetor: In-line fuel filter: Magnetic oil Drain Plug KLR650: PC racing stainless steel cleanable oil filter: Carburetor vacuum hose snorkel upgrade:Chain, drivetrain, wheels:108 link DID 520VM Gold Premium X-Ring Chain: KLR-650 PBI high strength reversible front sprocket 200,000 PSI: Touratech TL-1213 Aluminum Tire Lever w/ 12-13mm Box Wrench: Touratech TL-24 Aluminium Tire Lever with 24mm box wrench: TPI PO0838, AXLE CLIP front and rear: Moose Racing - FAG HRS series sealed bearings rear wheel PO0841: Moose Racing - FAG HRS series sealed bearings front wheel PO0840: Suspension:Multisurface motorcycling 8.0 kg rear shock spring: Frame: All load bearing bolts upgraded to Class 12.9 alloy steel for maximum strength and shear protection. Stronger than Grade 8 US bolt standard; 180,000 PSIEvery single bolt torqued to factory specs and loctite threadlockedEnamel marker on all vibrating bolts for quick daily checksEagle Manufacturing Idler Shaft levers and spring (doohickey) upgrade: TPI Drill Through Subframe Bolt Upgrade Kit for KAWASAKI KLR650 CY1750-2: Electrical: Mean Well Isolated DC/DC Converter 15W 5V 3A SD-15A-05: 12V cigarette lighter adapter above sprocket waterproof12V cigarette lighter adapter in top case USB power outlet 3 Amp in top caseMotorcycle license plate bolts with LED lights: Dual Star KLR 650 LED Tail Light, high alert, low power consumption: Symtec Heated Grips Kit: Mouser 633-WT11S-RO and 633-AT4181 Waterproof switches (IP67 rated) for heated grips and mains: Ancor Marine Grade Primary Wiring, heat shrink tubing and marine grade butt connectors for all electrical connections 12AWG and up.-----------------------------preventive maintenance and consumables (less than 2000 miles ago)fork seal and bushing replacement OEMfork oil replacement OEMKeihn carburetor jet replacement and cleaning OEMoil replacementgenerator cover gasket replacementwater pump gasket replacementdot-4 brake fluid replacement engine air filter cleaningTouratech heavy duty inner TUBE-21 3.00 x 21 Tube front wheel: Touratech heavy duty inner TUBE-17 4.00/5.10 X 17 Tube rear wheel: TPI motorcycle OEM clutch cable PO0010-1, CABLE, CLUTCH, UP TO 07: ----------------------------Safety: bypassed side stand ignition switch mains shut off for the electrical systemblinking LED brake light, side reflectors on swing arm and forks for better visibilityengine protection crash bars and alloy skid plate under engineloctite, manufacturer spec re-torqing and visual marking of all load bearing bolts center stand for easy tire changes on the road side.