Devil's Creek 2019

The date for Devil's Creek have been announced.

Devil's Creek starts the annual American Motorcycle Association Dual Sport Series. There are three levels, Adventure, Discovery and Dual Sport.The KLR650 has been at the last three Devils Creek Rallies following the Discovery Track.

2016 Devils Creek Post

2017 Devils Creek Post

2018 Devils Creek Post

Side Stand Switch Bypass

I removed the side stand switch today. It's definitely a good safety feature (as is the clutch switch) but it just doesn't fit for a pure rally bike that I have planned for the KLR650. Generally, one wouldn't expect any problems. On the trail though, wire damage, mud and crud in the mechanism and you're stranded trying to figure out why the bike doesn't work. All that is to say, I couldn't recommend doing it on one's normal ride.

So, below is the side stand switch that's under the plastic cover on a Gen 2 side stand bracket. Essentially, it cuts the engine if the side stand is down when the motorcycle is put in gear.

The switch's dual wire lead runs up the main frame to a connector.

While there are a number of ways to bypass the switch, I simply cut the lead and crimped the two wires together and then reinstalled the connector. That completes the bypass.

Of course the switch was saved should I want to put the bike into normal service in the future or sell it...both of which are doubtful.

Now, as mentioned above, there is also a clutch switch located in the left handle switch box that prevents the motorcycle from being started while the clutch is out. Many rally participants bypass that switch as well. However, in my view, that switch is not susceptible to the types of influences that the sidestand switch is susceptible to (damage, mud, crud), so I don't see a reason to by pass it. While those that do the clutch bypass generally agree with my thinking, they believe the risk of an outright malfunction of the switch makes the bypass a legit mod. Okay.

KLR 650 Restoration Part 3

The status of the KLR650 is Good-to-Go...finally.

As discussed in KLR 650 Restoration Part 1 and Part 2, I was forced to replace the entire top end after it suffered catastrophic internal damage that likely arose from oil starvation. I purchased and installed a largely intact 2013 top end that the vendor represented to have under 5,500 miles.

More problems identified and addressed:

Following my last report (KLR 650 Restoration Part 2) I ran into a big problem having found coolant in the oil. I noticed the frothy-white through the oil check window, which is an indication of significant moisture in the oil. That was over a month and a half ago.

After consulting with other KLRistas, we decided that the head gasket (which I did not replace in the top end replacement) most likely blew out. So I tore the whole thing apart...again...and replaced the head gasket. The problem persisted.

The only other source of coolant is the water pump, which has two seals, one on each side of the right case/clutch cover. The inner is a basic seal for the impeller shaft and the outer is a mechanical seal with a spring that opens and closes to relieve pressure through a weep hole on the bottom of the water pump. Well...when I got it apart, I found that the weep hole had been plugged...purposely.

Onward....

My attempt to rebuild the water pump failed twice, damaging two inner seals. That is one miserable item to replace. I finally gave in and got my dealer involved. After their inspection, they determined that that impeller shaft was bent. Crikey! Did I do that? Maybe, I don't know. However, I had them do the repair. So, more money than I wanted to spend, but we're good now.

On the coolant in the oil, there were a number of discussion threads around where owners tried to describe what the frothy mix looks like. The next two photos are the same drained fluid. The first photo is upon drain and the second photo is after a few minutes. Since oil floats on water, after a few minutes the mix of foamy oil-water separates with oil on top. There you go...

Ready for the trails:

Having decided to put the KLR650 back into action, starting at the Wild Bear (New Smyrna Beach) in a few weeks, I also added some additional items to the restoration:

Dunlop D606 DOT Knobbies, tubes and strips
Tusk Front Crash Guards (1)
Enduro Engineering Roll Chart

Primary Drive Chain, 15T Countershaft Sprocket, 45T Drive Sprocket (RMATV Kit)
Eagle Mike Prevailing Torque Countershaft Nut
Fresh OE Brake Pads (front and rear)

Wild Bear Safari (Ocala National Forest) 2017:

Wild Bear Update

The KLR650 is back together and has been checked out by my dealer (TampaBayPowersports). With a little additional assembly, a few missing parts and touchup on some plastics damage, it will be ready for action.

Today, I signed up for the Wild Bear Dual Sport Safari out of New Smyrna Beach. I rode this rally with my son (on the KLR) last year. We'll be tracking Ocala National Forest on the 8th and 9th of December.

Maybe this year we'll see a bear.