The bike I'm going to build

[stinkwheel]

Been thinking about this and got a few suggestions from folks on here a bit ago.

I have a pretty good idea of what I want out of a bike now and short of a 1200GS no-one makes it. So, here is my plan.

Buy a KLE500. Preferrably one with a blown engine, can be pretty scruffy.
Fit one of my GPZ500s engines in it (I have two).
Spend some money on the suspension, possibly some valve-work on the front and definatley a replacement rear shock with remote preload adjustment.
Put a proper metal bash-plate on it.
Fit a big huge enduro fuel tank.
Fit luggage racks to take my hard panniers.
Fit the cast wheels out of my newer model GPZ500s.
Fit twin radiators with multiple fans or possibly an oil cooler
Paint the whole lot matt black.

This should give me a motard style bike that is big enough for me, will cope with shitty roads but has enough go about it to cover motorway miles in comfort and do a bit of thrashing when the mood takes me. It will have a big tank range, should carry a shedload of luggage with ease and retain a reasonable tyre choice.

The original wheels will be retained for if/when I decide to do any adventure biking, the extra cooling capacity is for this too as those engines get pretty hot as standard unless you keep the road speed up.

The engine choice initially seems a bit odd, but the gpz runs in a very forgiving manner at lower revs. Should be fine for the odd gravel/dirt road and a bit of very tame cross country stuff (which is all I would be attempting on such a heavy thing). Then when you get back onto tarmac you can open the thing up and cruise at 90 without rattling your teeth out.

So. Anyone got a blown-up KLE500 for much cheapness that could use a bit of work doing on it?
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[VFR400UK]

Sounds good, i recommend you get some big paniers possibly from a beemer for it!

[Robby]

Fitting the tank off an XT600 tenere then? I think thats one of the biggest production fuel tanks.
Also instead of twin rads can't you just fit one really big one.

[J.K.R]

Ive got a xl 600 tank lying about somewhere, sure it only needs a cap (taps are still there)

Yours for £10?
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www.oldskoolsuzuki.info

[WildGoose]

sounds like a damn interesting project

whats the story with the baghira tho? still getting no joy?
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So in other words, he stopped you for being flagrantly in posession of a motorcycle in direct contravention of the Hippies, Darkies and People Whose Face I Don't Like The Look of (Police Powers) Act. 1976

[stinkwheel]

[stinkwheel]

Undecided on what tank to use, hopefully a kawasaki one of some description, more likley to fit. I believe they did make some pretty huge ones for the KLR at one point and I suspect the two models will have quite a few parts in common. Having bodged tanks about between makes before, I know that they LOOK like they should fit but invariably don't without a fair amount of hassle.

As to the radiator thing. I like the idea of two, for one thing, I might land up with it being over-cooled for in the winter as carb icing used to be an issue with these engines, it would be relativley simple to blank off or even bypass the second radiator. It also gives built in redundancy to the system. Say I holed a radiator in the middle of nowhere, you could move the pipes about and continue on just the one.

Anyhow. First step is to find a donor bike to use as a chassis, without that I will have no idea how and where everything fits.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[J.K.R]

Was just thinking that, Xl 600's are air cooled

My transalps on a matt black theme though (ill get pics soon!)
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www.oldskoolsuzuki.info

[MarJay]

Stinkwheel,

What about an older tiger with a cast wheel conversion?

https://www.triumph-ant.co.uk/images/bikes/TriumphTigerWithOneOfOurThreeSpokeConversions.jpg

Large tank, grunty motor, good suspension, sportsbike wheels, good for luggage... what more could you need?


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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F; Cheap project: CBR900RR FireBlade
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[Visitor Q]

I have a mate hybridising a TZR 250 Engine with all the gubbins of an RGV 250.

Had loads done to it by harris, bracing bits, chopping bits,

Hes quite insane. And then... he wants to tour france on it if its running before august.

He has a K4 GSXR 600!

But he lives in a truck so ill let him off.

And i agree with marjay, that triumph would work.

Tell you what you could do for all out natty-ness, bastardise a sports bike with off road suspension and tyres

I have a dream... That one day.... when im rich...

I will put knobblys on an R1 and rag it round a feild.
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China traffic/travel bike vid - When I make a sweeping statement, please add the word 'statistically' in to the sentence before you bitch...
From September 2014 to January/February 2015 I will not be using any English, nor reading any. As such, I won't be on here. PM at will, but I won't be checking/posting unless in emergencies. Certainly not for the first couple of months. Please berate me savagely if I break that rule...

[stinkwheel]

In real terms, those triumphs are no faster than my GPZ500 and a damned site more expensive.

I know this because my mate has one and after a flat-out blast of some 100 miles up in the highlands, he couldn't shake me...much to his consternation.

I am also still uncertain about the reliability of the Triumphs. They seem to get stupid little faults with a minor componant which then stops you riding it.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Kickstart]

[mr.z]

Will be watching this with great interest

With the fuel tank,

https://www.old-site.africanqueens.de/_html/prod_e/kp_tanks/kpt__501.php3

https://www.old-site.africanqueens.de/_html/prod_e/kp_tanks/kpt__601.php3

These will probably cost more than the actual bike, but shows how much can be carred!

Ideally you should have 300miles+ capacity for a "adventure touring" bike...

Assumeing your looseing the back seat you could modify the subframe to take an auxiliuary tank equal to your main tank at least, 40l total should be enough!

https://www.pplmotorhomes.com/parts/lp-gas/30-lp-gas-cylinder.htm

You could use upside down domestic gas cylinders, make your own hoses and fixtures for it and link it to a fuel pump... main tank runs out? fuel pump on, refill main tank...

They are cheap, will take a serious smash to damage significantly, and are pressure tested so totaly fluid tight, might be worth putting in some petrol resistant rag or something or it will be sloshing allover the place...
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>RidingSkills<->Tech Tips<->MyBikes<

[Gob]

I'm about start almost the same project myself on my recently purchased 2004 KLE. May sound stupid to modify an almost maiden bike. Yeah, right.

I'm keeping the engine as it is. some people suggest modifying the carb settings to bring it back to GPZ performance but my mechanic suggests the opposite. I'll stick to his advice as long as the engine keeps ticking properly.
The 2004 KLE has preload adjustment so I'll have it tightened to its limit. I've heard the front suspension can take as much as 35 psi air pressure, though it may be wiser to keep it somewhere between 25-30 psi (twice the recommended pressure) in consideration that the thing gets stiffer as you ride due to heat buildup.
I think the existing bash-plate is doing alright. What exactly do you have in mind?
Probably we both need a home-made solution for the fuel tank because as you also say, KLE doesn't get half the accesories the KLR already has. I favor a rear tank kit similar to AT or the XR solution. The KLE's center of gravity is already way too front, so it might be a better idea to shift it rather backwards.
Good luck with the panniers. I prefer soft bags in the rear.
Tech people suggest using spoked wheels if you want to go offroad. I've heard horror stories abour cracked or even broken cast wheels in some rough terrain. Dunno, you decide.
I will mount a second fan, thanks for the idea. Twin radiator option seems interesting but it sounds like adding more weight.

Further, I'll change the spark plug with a hotter one for better offroad performance. The fairing including the headlight and windshield will be removed. The indicator panel presents to be a problem, would probably stick it somewhere else to make room for the headlight (which will probably be a Honda CG headlight, which is the cheapest around). The rear rack will be removed and the signals re-arranged. Will mount a KLR styled front mudguard. I'll simply remove any additional seemingly useless parts to reduce weight.

We start this saturday. I can send you some pictures of the progress if you like. Good luck with your project.

[stinkwheel]

Sounds very interesting.

I'll not pick faults because you seem to have a good idea of what you want. Just one thing though.

CG headlamps are Shit (note capital 'S'). If you want a single, round headlamp, might I suggest using an LC style one. They are almost universal in their popularity and pattern ones are readily available. They also have the singular advantage of letting you see where the hell you are going in the dark.

I will most probably be using twin headlamps off a citroen 2CV.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.