KLRsys - Versys powered KLR

[tapntx]

That is an awesome project, until you look closely you would never know. That motor seems to fit in their really nice.

You did a really nice job

Todd

[MaverickAus]

Amazing job, well done

[fasteddiecopeman]

AWESOME, friggin' AWESOME!

[Yarne]

Very nice build up! I'm particularly interested in your installation of the Rostra cruise control as I could not find much current info. I've had one sitting on the shelf for over a year and any help (wiring tips) you could give me would be appreciated. Thanks

[KLRsys]

Originally Posted by Yarne

Very nice build up! I'm particularly interested in your installation of the Rostra cruise control as I could not find much current info. I've had one sitting on the shelf for over a year and any help (wiring tips) you could give me would be appreciated. Thanks

I be happy to help. I need to dig around and see if I made notes but I can always look at my bike. I'm going to be doing another one in a month or so and I need to figure it out anyway. If you have specific question it would help. Which switch control do you have?

[Yarne]

Originally Posted by KLRsys

I be happy to help. I need to dig around and see if I made notes but I can always look at my bike. I'm going to be doing another one in a month or so and I need to figure it out anyway. If you have specific question it would help. Which switch control do you have?

The switch I have looks very similar to yours, it's a: dash mount switch w/eng. open circuit ( P/N 250-3592). The questions I have are what source did you use for the vehicle speed sensor hook up and where did you mount the servo? I have already got equipment mounted on the left hand side of the tank and hopefully would be able to keep it there. Thanks again!

[KLRsys]

Originally Posted by Yarne

The switch I have looks very similar to yours, it's a: dash mount switch w/eng. open circuit ( P/N 250-3592). The questions I have are what source did you use for the vehicle speed sensor hook up and where did you mount the servo? I have already got equipment mounted on the left hand side of the tank and hopefully would be able to keep it there. Thanks again!

For the speed sensor source, I used the LG/R wire (light green with red stripe) coming from the speed sensor to pin 6 on the larger connector on the ECU. I tee'd into in near the ECU end of the wire.

I mount the servo here.


I also abandoned the original switch set and put some in the right switch housing, easier to reach. This switch housing is off the Versys.


As I recall, I did not connect the tach wire (blue?) and the instructions said to ground it. When I did that, the cruise wouldn't work, so I left it disconnected.

[Yarne]

Originally Posted by KLRsys

For the speed sensor source, I used the LG/R wire (light green with red stripe) coming from the speed sensor to pin 6 on the larger connector on the ECU. I tee'd into in near the ECU end of the wire.

I mount the servo here.


I also abandoned the original switch set and put some in the right switch housing, easier to reach. This switch housing is off the Versys.


As I recall, I did not connect the tach wire (blue?) and the instructions said to ground it. When I did that, the cruise wouldn't work, so I left it disconnected.

The servo mount looks factory, nice work! I will attempt to do something similar on the Versys, if clearances allow on the opposite side attaching it to the bracket from my custom topcase mount which uses a Honda 600RR mounting system. Think I'll also fab up a shroud and grommet to keep the wet and road junk away from the connectors. You're right, the original switch mount must have been a bit of a stretch to engage and keep the throttle where you want it. Think I'll mount on the left side, along with the hot grips control switch. Thanks once again for all your help; this forum is invaluable to us Versysites.

[KLRsys]

Originally Posted by Yarne

The servo mount looks factory, nice work! I will attempt to do something similar on the Versys, if clearances allow on the opposite side attaching it to the bracket from my custom topcase mount which uses a Honda 600RR mounting system. Think I'll also fab up a shroud and grommet to keep the wet and road junk away from the connectors. You're right, the original switch mount must have been a bit of a stretch to engage and keep the throttle where you want it. Think I'll mount on the left side, along with the hot grips control switch. Thanks once again for all your help; this forum is invaluable to us Versysites.

I slathered the electrical connection with liquid electric tape (after this picture was taken). I figured there wasn't any way I could keep it dry that close the the rear wheel, so I just tried to make it waterproof.

When you get it done I'd like to see how you connect the cable to the throttle bell crank. I had a custom bell crank already because my throttle bodies are mounted upside down so I just added another groove to it for the cruise cable.

[Yarne]

I will definetly post pictures when I get all my ducks in a row...I have lots of metal working tools, just not much time to use them, but you have inspired me to get at it!

[Don't_Stop]

Originally Posted by dfmcse

I had a 09 KLR for a bit but I didn't like the underpowered motor. Everytime I got in traffic I felt like I was about to be run over. I move to Versys and I'm much more comfortable in traffice. I still ride the back roads with the Versys but I do have to turn around more. If my KLR had had a Versys motor I'd still have it. I'm very impressed with what you've done.

One day, I pulled up to a red light beside an old couple in a Benz and thought that as the light turned green, I would get around them on my KLR and make better time. They didn't even floor their car but, I could tell, just stepped on the gas some and I could not pass them on my '07 KLR. They ended up still in front of me as the road narrowed back to one lane again. That was the very day I decided to get rid of the KLR. It sucked on the road and it pretty much sucked in the dirt too. (Not to mention all the little problems the KLR has that you have to fix: like the doohicky. If you've owned a KLR, you might know that the doohicky is the spring loaded cam chain tensioner that sometimes fails to adjust the tension or runs out of adjustment causing your engine to self-destruct. )

[Jdcooper]

This is a wonderful build. What is astounding to me is why nobody at Kawasaki has thought of it. The KLR is hopelessly antiquated and the Adventure bike genre' is booming. Cruisers are dead. You'd think the combination of V and KLR was a logical product maturation. What are they thinking over there...????

[BigOleChalupa]

Originally Posted by Jdcooper

This is a wonderful build. What is astounding to me is why nobody at Kawasaki has thought of it. The KLR is hopelessly antiquated and the Adventure bike genre' is booming. Cruisers are dead. You'd think the combination of V and KLR was a logical product maturation. What are they thinking over there...????

I agree with you JD, that yes, they could certainly do something more so along the lines of a V/KLR mix, but cycle world magazine, in their recent issue, just did an Adventure motorcycle comparasin based on which ADV bike the different riders would take if armageddon ever happened.
Anyhow, they had the Tenere, the Tiger800, Husky650, ktm 990, and the KLR.....
The KLR ended up being the winner!! Must be doing something right

[fasteddiecopeman]

Originally Posted by BigOleChalupa

...Anyhow, they had the Tenere, the Tiger800, Husky650, ktm 990, and the KLR.....
The KLR ended up being the winner!! Must be doing something right

Might just have something to do with the fact that you can repair that OLD technology with a screwdriver and a hammer...

...and a bent paper-clip!

[KLRsys]

KLRsys II has been on the road awhile now. Thought I'd put up a couple of pics.
09 KLR with 09 Versys powertrain. Not quite finished but getting close.







Build photos