2008 KLR Diesel enduro Build!!

[Deezil]

This Is not mine..........

A Guy Posted his Build Over at the Chinriders Forum I am on. I mentioned the Dieselbike.net site and the forum link but he has not made it over here yet.

You should be able to check out his build over there. 13hp and comet driven....

Maybe we can get him over here to do a write up!!!

Heres the link.

http://www.chinariders.net/modules.php? ... sc&start=0

[dieselbikin]

What a cool bike! The top picture looks like a factory build. The most interesting part to me was the the top speed claims. What do you guys consider your "top speed". I have a steep downhill on one of my test legs that I have hit 64 MPH. However, on my relatively flat test leg the topspeed reached was 58 MPH and the average speed was 51 MPH. I have an accurate bicycle computer that I reset for each leg. I start the computer and measurement from a dead stop, so that accounts for some of the disparity between top and average speeds.

Speaking of HP ratings:
The Winsun 13HP 456cc engine is rated at 8.3KW = 11.1HP.
The Punsun 10HP 406cc is rated at 6.7KW=9HP
Horsepower difference 2.1HP=19%
Displacement difference 50cc=11%

[Sphere]

He doesn't claim 65mph, that's the dude selling his bike on craigslist. This guy uses that bike for inspiration.

[SamM]

I'm the guy building the 2008 KLR Diesel enduro bike. It's true that I am using Sparky's bike for the inspiration for my own project. That bike looks just about perfect to me. Maybe a little heavy! The 2008 frame that I'm using is going through a serious weight shaving processes right now. It will be much lighter than Sparky's bike. I'd like to see 65mph or maybe a bit more but I am scheptical about any topspeed claims. It makes sense to me that the lighter the bike the more I can get out of it. That might be some flawed thinking but hopefully it will work. If a part doesn't bring something to the project then it won't be on my bike. I'll start a build thread when I get further along.

Here's a picture! The bike has a 2008 Kawasaki KLR650 frame, a set of 2008 Kawasaki KX450F inverted forks and a Cogent Dynamics 'MOAB' rear shock. The suspension has been reworked for 9" of travel. I've decided to go with a 2007 KLR swingarm. Thanks for looking!

SamM

[Sphere]

Hey SamM. It shouldn't be much heavier than an Enfield? And you get an amazing 23L tank. Filled with diesel it will give you an enormous radius

[SamM]

Sphere,
I have a 6.6 gal IMS tank that actually holds closer to 7 gals. The range with it would be incredible. Here's a picture of the bike with that tank. This was my project until I saw the diesel bike that Sparky built. I stopped on that project immediately and started the diesel build.

More later!

SamM

[SamM]

One more thing. Here's the bike that I built with the parts from the original KLR and the leftover gasoline engine. I plan to add a Dauntless Enduro sidecar to this one for Winter riding and new 18" Excel wheels.

SamM

What I started with


What I ended up with

[Sphere]

Please try to document any changes you have to make to the frame to make the Yanclone fit. This is what has been missing from the Adelaide BioBikes. Good luck!

[dieselbikin]

He doesn't claim 65mph, that's the dude selling his bike on craigslist. This guy uses that bike for inspiration.

It was not meant as a jab. Maybe I should use more emoticons. LOL. My major focus during my build has been top speed on a "flat", so if there is more to be had out of my bike I'm very interested in learning how to get it. I simply wanted to know if the KLR can cruise down the road at a consistent 65 MPH or if it has simply hit 65 MPH on a downhill at some point in time like my own bike.

My everyday bike is a 1991 Suzuki DR650S. I ride about 6K miles a year and want my own 2008+ KLR650 once finances allow.

[Sphere]

I didn't take it as a jab, its just that the dude claiming 65 mph is not SamM. I meant to clarify that; it seemed as if you thought he did. And 65mph seems unlikely if I hear what the Enfield crew is getting with 10-11 hp and you with your suzuki. While we are on the top speed topic, perhaps it would be helpful if you started your bike computer on the flat at top speed to get a real feel for average topspeed. I am very keen to learn what that figure is.

[SamM]

Everything is cool! Nobody is jabbing anyone!

The original KLR diesel enduro bike has a Comet Series 40 CVT. My bike will use a Comet Series 500 CVT. I contacted Comet/Salsbury directly and they recommended the Series 500 to me for this application. The 500 CVT is available with an overdrive. The overdrive will hopefully get me a higher topspeed. We may have to fiddle with the sprocket sizes to get what we want out of it.

The one problem that I do foresee is that the bike may need to be converted to a rightside final drive. If that needs to be done the bike will require a custom rear disc bracket. Custom spacers may also need to be fabbed.

I also need to mention that I am parting out my 2005 KTM 950 Adventure. As I sell parts I will buy parts for the diesel conversion. I didn't really want to post this early into the build because it may take awhile. Hopefully, you guys are a patient lot!

SamM

[TedV]

I’ve started wondering about the performance of the 13HP with a comet 40 in a KLR as soon as I saw the pics of the diesel KLR for sale. How soon before you have it up and running? Looks like a great project. Can your backside put up with the seat long enough to empty that 6.6 tank full of diesel in one run?

Did you measure to see how a 22hp to 25hp V-twin would fit the KLR frame? Looks like the frame tubes were changed in the pics of the inspiration bike to make the single fit. Not sure what dual sport frame would work best with V-twin and CVT.

Doh, you added a post before I posted the above. Hmm, I will have to look at the comet 500. I think I would miss shifting, but if the engine will last longer since it’s made for constant speed, the CVT is a better match to the motors. My girl friend likes the thought of a dual sport and with a rim/tire swap, it’s a motard. I still don’t know what I will build. At least you have a plan and started getting parts.

[Stuart]

Great looking project there Sam But TedV is right to ask if you sized up a V-twin lump as they give better real would performance with the 20+ hp. 10hp is fine for getting about on provided you're not too concerned about top speed and live in pretty flat country. 20hp will bring you in line with most other vehicles on the road as regards ability tough. Saying that, they'd probably be so heavy that you bike would ride low and your figuring on the suspension would have been for nothing
Given how long it's taking the rest of the automotive industry to catch up with our way of thinking we have to be a patient lot around here

Best of luck with the bike

[dieselbikin]

A Suzuki DL650 or DL1000 would be a good choice for an off-road v-twin frame. They come with V-twins from the factory. Can you imagine going 800 miles on a tank of fuel!

[SamM]

TedV,
My timeframe on the build depends on how quickly I can generate the funds to buy the engine and get the frame mocked up and welded. Putting the bike together is not that much of a problem. There will be some trial and error with the CVT fitment and getting the sprockets right. Paint and finish work will be left for the Winter months. If she's up and running by Spring I'll be happy. I have other projects, so there is no hurry.

No, my backside won't handle that much seat time! I'll probably go with the smaller 2007 KLR tank that I also have.

Yes, I've looked into both the 22 & 25hp V-Twin engines from Punsun and Winsun. Neither will fit in my frame. The KLR is just too small to install a V-Twin engine into. It would require a major rebuild. I don't believe that those engines make enough power compared to how much weight they bring to the build. These are very heavy engines. I'd love to use one of these in a Harley cruiser type bike with a 6-speed Baker transmission or maybe a liquid hydrodrive. That may be a good future project.

I like the KLR very much. It's a great platform for whatever type bike anyone would like to build. Everything from a trailbike to a Supermoto bike, and from a touring bike to a short mileage commuter. It will do just about anything because it's so versatile.
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Stuart,
The topspeed is a concern and I live in VERY hilly country. However, my commute is realitively flat and on a twisty 55mph 2-lane. I used to ride a 50cc Yamaha Zuma scooter with a 45mph topspeed to work. It was stressful but I never had any real problems. I only have one large hill to climb. After that it's all downhill into the city.

Thanks! I hope it goes well too. I'll keep you guys posted. I'll be sourcing a few parts this week and getting some small jobs finished.
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dieselbikin,
I somewhat agree with that. One of my bikes is a KTM 950. That frame would be a good choice, if it wasn't a trellis frame and if it didn't use the engine as a stressed member. Adding a lower portion to the frame wouldn't be that hard to do.

Thanks everyone!

SamM