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Unread 2014-04-21, 09:31 AM   #26
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Eh, just shine it up by hand and throw her back together and get to riding
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Unread 2014-07-18, 04:49 PM   #27
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Haven't updated this thread in a while...

So, I got the bike all back together and went out for a ride a 2 months ago. I managed to get the bike up to the fastest speed I have ever gotten up to. I got up to 55 MPH. It was no easy feat and almost scary. It felt extremely light at that speed. Partly due to the suspension and partly because it only weighs 200 lbs. After coming back home I noticed a burning smell in my garage. I panic'd thinking about what just happened to my garage a few months ago. I tried to find the source of a fire to no avail.

I took the gas tank off and looked over the wiring in front of my eyes the ignition wiring was starting to melt. This is what happened.


There are no fuses on this bike so unfortunately it didn't stop burning until I unhooked the battery.

This just meant one thing, it was time to do a full restoration on this bike.



There have been some patch jobs to keep this old girl running all these years. Finally I will be fixing them correctly. I will be replacing any wiring that is suspect.



This is a picture of the starter/generator. Look at how crusty that wiring looks.



This is where I stopped for today. Taking apart all the brake parts and what not is very tedious and time consuming. Let alone the spoke wheels. I might outsource some of this work just to make things move along quicker.
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Unread 2014-07-21, 09:20 AM   #28
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Engine out, now it is onto the suspension.
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Unread 2014-07-21, 09:34 AM   #29
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Sweet!
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Unread 2015-05-13, 08:51 PM   #30
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Bike has been sent off to the Powdercoater. Bodywork is at the painter. Hopefully it will be done soon. Next up will be the motor rebuild. I got a CT1 (125cc ->175cc) cylinder and head. I will be cleaning up the ports for a little more power/torque.

I will post pics as soon as I get the parts.







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Unread 2015-05-13, 09:04 PM   #31
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Sweet!

I've got everything ordered and on the way for my XL 100, so hopefully it's road ready in a few weeks! Then I can bring it back up and we can cruise around.
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Unread 2015-05-13, 10:08 PM   #32
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Sweet!

I've got everything ordered and on the way for my XL 100, so hopefully it's road ready in a few weeks! Then I can bring it back up and we can cruise around.
I just hope I can get it all back together. Haha
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Unread 2015-05-25, 09:07 PM   #33
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Tore down the stock engine today. Everything looked pretty good. There are a few issues that will need to be addressed. The new cylinder I bought for the needs to be bored out and a new piston bought. Surprisingly this engine was actually in good shape. No play in the bearings, and the stock cylinder didn't have any scoring in it.





This crankshaft seal was on its way out. If I would have ridden this bike just a little bit more it would have blown up. This is a common issue with old 2 stroke engines. These seals will let go and run the engine lean, then BOOM.




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Unread 2015-08-15, 02:33 PM   #34
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Body work is complete:






There is absolutely 0 orange peel. The color was almost a 100% match. If I had to guess its around 98% match. The real paint color would have cost a few hundred bucks to get. I went with a like automotive color. They added a little dye to get it really close to factory color.

Randy's auto body did a great job.
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Unread 2015-12-23, 08:44 AM   #35
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Taking apart the wheels and sending them off to a polisher.

Here are a few pictures before disassembly:



Hub/Sprocket side:


Offset was about ~2.3"


____

Brake side:


Offset was about ~1.3"






These are just for reference.
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Unread 2015-12-23, 08:44 AM   #36
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Am I crazy or just intimidated by the spoke wheels. LOL. I don't know if she will ever see the dirt again after all this work.
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Unread 2015-12-23, 09:03 AM   #37
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Is this fast?
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Unread 2015-12-23, 10:11 AM   #38
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Unread 2015-12-23, 10:33 AM   #39
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Is this fast?
Up to 30 MPH from a dig on a Tuesday morning with 72 degree weather, and the motor built by Wilson Performance.
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Unread 2016-01-28, 09:22 PM   #40
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Time for some pretty pics...





I have to say all the pieces I had polished/cleaned up turned out great. Some of the pieces had rust, pitting, or were stained and almost all of it came out looking great. Keep in mind this bike was a true enduro. My father used to ride it to work everyday in the rain or shine. Then on the weekends it had trail duty. After all this work it should be good for another 40+ years. haha.
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Unread 2016-01-28, 09:28 PM   #41
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Does it run yet?
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Unread 2016-01-28, 11:55 PM   #42
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Does it run yet?
Lol. So funny, but no it does not run. I will be working on getting the frame together the slowly putting parts back on it. The wheels are the scariest thing right now. I have no clue how to really start on those.

I have some pieces that still need to be restored such as switches and the seat.
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Unread 2016-02-01, 09:08 AM   #43
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Getting closer. Main harness and core electronics are installed. Fenders, and suspension are installed. I hope to have the gauges, headlight and turn signals installed soon.
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Unread 2016-02-01, 10:52 AM   #44
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Looking good bro.

Trailer that to Austin MotoGP
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Unread 2016-02-01, 08:12 PM   #45
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Looking good bro.

Trailer that to Austin MotoGP
Shii. Have to ride that beast down there with a backpack and a few spark plugs. lol
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Unread 2016-02-01, 08:15 PM   #46
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Quote:
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Lol. So funny, but no it does not run. I will be working on getting the frame together the slowly putting parts back on it. The wheels are the scariest thing right now. I have no clue how to really start on those.

I have some pieces that still need to be restored such as switches and the seat.
I really want black wheels on the KLR, but I do not want to be lacing wheels. Fuckkkk that.
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Unread 2016-02-04, 01:49 PM   #47
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I really want black wheels on the KLR, but I do not want to be lacing wheels. Fuckkkk that.
I'm still concerned about this part of the project. I have no idea how to get the proper offset.
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Unread 2016-02-21, 08:35 PM   #48
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Unread 2016-02-29, 10:07 AM   #49
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I have found out some bad news on the spoke front. Since they were polished supposedly they will start to rust in a no time. Even if I clearcoat them they will still rust. That is kind of sad.

On the positive note:


Motor is in.
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Unread 2016-02-29, 10:12 AM   #50
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So it's a wipe them down everytime you ride kinda thing?
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