Project Boat Anchor ***Lots of Pics, 56k curl up and die**

[Gvilleracer]

Hi all,
First post and a new owner.
I have been trying to decide on a good dual sport for months and picked the KLR250.
I have a Buell Ulysses and a Husky 450smr and wanted something smaller to ride around with freinds and family.
The KLR seems to have all the things I wanted in the smallest possible package.

I couldn't find a realy nice one cheap; so, I went the other direction.

Say hello to Rusty, my 99' KLR two-fiddy.

Picked this up on Sunday off Craigslist. Couldnt bare looking at it anymore.... So me and a freind tore it down.
Now the re-build begins.

Mechanically and electrically, I think we lucked out; but, asthetically, this thing must have sat at the bottom of an ocean! It has rock solid compression and amazingly every light, switch, and gauge worked.

looks good from a distance



BUt on closer inspection.












Two beers after taking the above photos.......




There is my freind, Cam, this is our first DS re-build. So we wanted to start with an easy one, hope we did. We will try to keep updates coming as we sort the bikes issues!

It is not a runner, but the price was right. It would fire but stall within seconds and fuel was pouring out the overflow, ya for stuck float valves!
It has, like most barn finds, spent some time in storage with old gas in the carb. Judging buy the build up I found in the carb bowl, I would say it sat for close to one year.

Cam scored a bucket of carb/parts cleaner from work last night. The carb is getting dissasembled and cleaned tonight. Of course our carb has already ben tampered with I notice the brass plug is already drilled out and the plastic choke cable fatener thing is gone. So, now i have to find a way to secure the choke to the carb.

Things coming in the mail so far: via EBAY.....FTW
1. New brake and clutch levers.
2. new choke lever for left handlebar control, from KLR650
3.new throttle tube for a 96 KLR 250...hope it works.
4. UNI dual stage filter

hopefully this stuff will arrive shortly and we can start reassembly.

Cam stopped at cycle accesories last night:
1. renthal grips
2. new NGK spark plug

While we are waiting for these parts to arrive we will be doing a lot of grinding sanding and painting! hope to clean the frame up real nice

Things still needed:
1. RUN/STOP switch
2. fork boots or seal savers, havent decided which yet....
3. tires, going with the Kenda 270's in the big size.
4. Handle bar, might try the Tusk t-10, its cheap and strong once you add Acerbis metal gaurds.
5. mirrors
6. turn signals
7. battery
8. Exhaust pipe, the poor thing is rusted out and missing all the sheilds

If any one as spare parts or has found cheap deals on any of this stuff please let me know.

[XR Superman]

Looks like you've got quite a project. But it'll be worth it in the end. At the rate you're going it'll be finished before you guys finish that 6 pack. 

[BakonMoto]

  Gvilleracer!!!

Looks like you and your buddy have your work cut out for you, but it also sounds like you're up to the task. I lean towards the Super Sherpa myself, owning 2 at the moment, but there are several KLR250 gurus that can answer anything you might need info on. And one guy on this forum that has done a recent total rebuild is Airvent, so he would probably be a good resource too, in a tight spot.

Best of luck with it and keep us up to date on how it goes,

Bryan

PS- I'm assuming by your screen-handle that you're just down the road in SC. There's lots of KLR-istas in western NC and upstate SC to ride with and get to know.

[JV]

  Gvilleracer! Was the PO's name by chance Capt Hook?

[waverlyhagood]

        Gvilleracer.   Looks like you have a big project ahead of you.   

[SLO-KLR]

Good god!!!!  I hope they paid you to take that poor bike. 

[Jjgres]

You can buy just the little plastic nut for the choke-cable--to-carb. Mine was busted too.  I think guys pull the carb and forget it's there.  Fragile piece.

[Gvilleracer]

I hope the project moves that swiftly. Cant wait to ride it.

The Super sherpa was on my "List" for a while. I like its simplicity; but, I just couldn't get over the kind of goofey looks. I know it gets the job done in the simpilest way, thats why it was on my list. But, eventually my vain side decided it wanted the military-style of the KLR. I want to make some longer camp trips, like a high-ish seat height, cant wait to outfit it with some racks, I also like the water-cooled hi-comp motor. I love small torqey motors, but, I have been wanting a zingger for a while, should be nice on the road.
The truth is, if the sherpa had come along first, i would have bought it too, it was tie for me.
I am actually in Jacksonville, Fl and need to update my profile.
The screen name just followed me from past forums....

I have no idea how they bent the lever like that without totaling the whole bike.....

In the world of craigs list, I prolly over paid for this bike by paying anything at all.
But, as the great Peter Egan preaches, sometime you just have to save one!

[Gvilleracer]

UPDATE

Last night was more tearing appart.
 Me and Cam got more stuff pulled off the frame, radiators, wiring, connectors.
Not doing to much to get it ready for the raddle cans; but, just enough.
We will tape off anything that needs it and throw a blanket over the motor.
We are not going to mess with the engine too much. It has zero leaks, good compression, and the rear suspension actually feels real good and I don't want to risk pulling it apart, fingers crossed.
I snaped that temp sensore in the bottom of the right radiator , So, if anyone has this part please let me know.

The wife joined us last night and taped off the front rim so we can hit the spokes and hub with some primer and flat black. The primer has chemical etching stuff in it, so I hope this works. I think black spokes will look tuff; but, the paint may just fall off in a week.

My dad actually spent some time digging in the carb and found the plastic tip on the float valve is groved. I am kalling Kawi after typing this to asses the monetary damages. Otherwaise the jets seemed clean. I have not got to see the diaphram yet cause those little screwes are so rusted on! They spent all last night getting shot multiple times with PB-Blaster, dear-ol-dad will be trying to open it up again today. He is our carb guru.

That is it for now, me and the wife plan to adjust the valves tonight, updates to follow!

[waddskee]

At least Cam is hanging around to help! I would have been on my own the minute the beer was gone!!! Its a lot easier when someone is there to see where the wrenches land when you huck them. And you said he picked up parts too??? You must have some good vegas photos he doesn't want his girl to see!! Keep up the good work

[Gvilleracer]

LOL... tis true...good freinds are hard to find.
Its actually a joint project for us, we will both use the bike quite a bit.
Cam is more of a street bike guy, he loves his FZ6. But the idea of resto projects is our weakness.
I got a good deal on this hoping it would make a great loaner bike for freinds and family wanting join in the fun.
My wife has a DR200, which is actually the liitle bugger that sucked me and Cam both into getting small DS's.
I have the Husky to use when someone else wants to join in on the KLR....if its ever finished .

Buying a new float valve tomorrow....$36..... most expensive part-per-ounce on the bike!
That should revive the carb!

[waddskee]

I can relate to cam on the rockets!! I also have a 996 TLR and its hard not pass up on the horses, although the front tire doesn't seem to get much wear!! 

I also plan to get my wife off the quad and convert her to two wheels. 

Keep it up, you can never have to many good friends or sweet bikes!!

[Gvilleracer]

Ok,so here's how the weekend went down.
Every time one of us said "There is no need to take that off"...the other would say "but it would be easy, c'mon, its two bolts..."

which lead to this!

Yes, we were very proud to display our victory.....let me explain the carnage...

when we left off last time, the motor was still in as well as the front end and swing arm.
The plan was to tape everything off a spray bomb our little trail beater.
Well, Cameron!!!!! wanted to do the job right...blah blah balh
So, we decided to pull a few more things(I knew no good could come of this)

Out comes the motor along with a few broken bolts!
The bolts that hold the plastic cover over the front sproket broke when I looked at them!


Eww


Well with this great feat accomplished. Cam took a moment to ponder the possibilties..
Who says a 250 cant compete at the salt flats!


Off with its head! Bearings are in great shap, so a clean and re-pack is all thats needed here.



Now, this is when tools started flying out of the garage, into streets, and children playing near by learned new vocabulary!
Time for the swing arm to come out!
Easier said than done when working with a rusted relic that was obviously dragged behind Noah's Ark!



After many beatings with a sledge!


30 min and two cans of PB Blaster later...
Dude, I'm telling you I soooo moved it and inch!!!!


I did what I could to save the threads, but I just cant resist a high grade steel!


Its def muffed. So I ordered a new one off ebay for $4.95 that will arrive soon, I hope.


Cam really wore himself down beating this one out!......hehehehehehe


PS, if anyone doesn't already know (we didn't) here is where your rear adjuster is on the shock. under a small plastic cover.
And 5lbs of soil that has turned to a clay brick if your bike is like ours!!!


So, this is what lead to the display of grousome destruction hanging from the tree like 3rd-world lawn art!
We got some sort of satisfaction from showing the whole three cars that past by our acheivment... We are man!

Just in time... my wife showed up to help the two gorrilas re-assemble the crippled machine.
And she comes bearing gifts.....Subway $5 foot-longs

Now don't start singing the commercial tune, stay focused here!

After we wipped out a few subs, we got back to work!
Christa taped up the rear rim for paint, covering the rim and brake areas. Since the spokes and inner hubs will be flat balck.
I started painting up side covers and little what-nots.

So, wifey seeing that all was going fine decided to go home and do somethig of greater value (closet sorting!...Ooooooo)

and Cam...where is Cam...

Captain Bolt Snapper Attack!!!!!


After much air grinding, sanding, cleaning, it came out real nice.
But, we have picked a paint that was a tad to Silver, not the aluminum look we anticipated.


So, we got a few other things primed and painted; but, things moved so fast we failed to take pics!

Dad actually finished rebuilding our carb and gave that to us.
Knowing that we were going to be runnig the airbox mod and a Jardine pipe. Which is quiet but slightly better flowing than stock.
He decided to fatten up the low speed circut from closed to 1/3 throttle.
Adding some fuel here will keep response and low end torque where it should be, as well as cruising temps low.
By having a little extra unburnt fuel to pull heat out. I know this sounds wastefull but...
I can't stand lean-pops on decel, so he wanted to be sure their wern't any!

We spent a few minuets picking at dad for using Harley parts in our carb.
He found that the rediculously lean pilot jet from a 883 Sportster could give us just the flow our 250 wanted with mods.
That, and it was laying there and ours was clogged beyond beleif! So, I'll let ya know how it runs!

Then a sound rolled into the garage with a presence that could only be created by the clanketty thump of a classic British big twin.....
Or Christas' GS500 with a blown out Yosh pipe, LOL. (its bark really is much more respectable than its bite)


Wife had to stop by to make sure that we ate a healthy meal!


All in all we had great weekend and enjoyed working on the bike with freinds and family!

[waverlyhagood]

   Gvilleracer it looks like you have a bad case of Rico idiss.       

[Gvilleracer]

^^^^
Do a lot of people catch this when they fail to walk away from a purchase they know they should???

[SLO-KLR]

   Gvilleracer it looks like you have a bad case of Rico idiss.       

That stuff must be really contagous because Hondo caught it too! 

[waddskee]

It's contagous and there really is no cure!! I have had it a few times. The worse part is when you have new toys and you start tearing those apart!!! Speaking of...I just put the needle nose to use on my 7 year olds top tooth!

[waverlyhagood]

  As SLO-KLR said it is very contagous.   One of the signs of this contion is when you plan on simpley washing your bike or doing a very simple task and end up with your ride in several pices. There is not a known cure for it. So don't fight it.     

[Gvilleracer]

The Gods must be angry!

This week has been completely unproductive! Not that we haven't tried to get stuff done!
Me and the wife were in Cam's garage on Tuesday and Thursday night this week.
But, all the easy stuff took way to much time! I guess we were bound to hit stormy seas soon though!

The work was very aggravating and my wife could only snap pics in between the feuds of rage, so, sorry for the lack of pics.

But it all started with the spark Plug. Yes that damn, rusted, stripped, and undoubtedly fouled object that defines internal combustion.
Why Zeus saw it fit to hide his lighting in such a deep tight cavern, I have no idea. But getting to it was going to be tough!
Of course, my original tool kit is long gone, I figure it must have become dislodged when the KLR narrowly missed being rescued from its water grave by a passing shrimp net. With that tool kit goes the cheap stamped steel spark plug wrench, possible the only thing known to man to fit in the head!

So we rummaged the tool boxes for a deep well 19. Yes, you heard right, I did say 19mm! The end result of years of rust left unchecked! This of course would not fit all the way down into the plug well but it did manage to knock enough rust off to return the plug to original 18mm size! After digging two 18s out of our boxes to find they are just to thick to fit. We made a trip to my dads to borrow his thinnest 18mm.
Nope...his was to thick to.

Is Advanced still open???? The part guys graciously let us behind the counter to compare our 18 to the ones he had.
He even took a few out of their wrappers. One was thinner; but, only just so. We had to try it, and we did......still to fat!

There was only one thing left to do and neither of us were proud of it!


About this time Cam's roommate, who just happens to be a veteran machinist for military helicopters and many other machines, comes walking into the garage to see how progress was coming along. The look in his eyes said it all! we have out of balance grinder that slowly walks across the desk as you use it, grinding a socket down to the weakest possible thickness, and not a stitch of safety equipment in sight. Well, he did have compassion!

Seeing that we are obviously misguided youth, having no comprehension of the effect of tools ripped out of our hands or a grinder overheating and sending shrapnel into our chest. He decided to lend a had. It was cool to see his interest in our project. But deep inside I suspect he simply felt that he couldn't bare to see to young men impaled by a flying extension! That is a true martyr people!

Well this is where we decided to stop.


It finally fit, the plug was frozen in very badly; but, it amazingly held together and pulled it out.
I will never loose this tool now, it will be needed many times in the future.

Oh, BTW, Cam went to cycle gear the next day and they sell the exact thin wall socket we needed. So, all was for naught!

We decided to clean out as many large pieces of rust as we could to keep them out of the chamber.
So Cam being so intuitive grabbed some Q-tips and then we shot some air down there.


We found some great news though, the owner before Noah must have cared for the bike a little.
It has a brand new chain and tensioner in it. As a matter of fact, we think the whole head may be new. Well, new from a salvage yard judging by some chalk writing we found on the head marking parts. This was possibly the cleanest motor interior I had ever seen. No wear marks on the cams, no dirt or grim, and not an once of sludge or burnt oil anywhere. I felt very reassured by this. And as we mentioned before, the bike had great compression. Which meant a lot considering how out of spec the valves were.


I was able to slide a .015 under both intake and exhaust effortlessly.
The few times I have got the motor to run, I did not think the valves were loud; but, they will definitely be quieter now.
The intake side was very easy and only took about two adjustments
The exhaust side took about 20; but, we blame the varying accuracy of a Harbor freight torque wrench for this!
In the end, I set both sides to a fairly tight .008. I am happy with that considering this is the first valve job We've ever done.



Thursday didn't go much better. But, this was more of a motivation issue.
Working on the bike fell second to disposing of the Bud Light with Limes that Cam left unguarded in his fridge.
In between conversations about the effects Body Builder shakes could take on Cam ass, we did manage to clear the frame.
On a tip from my dad, we picked up a can of Dupli-Color Engine Enamel Clear. He said it would tone down the shine of our molten silver and gain the appearance of Honda side cases......It sure did, and looks absolutely awesome! I hope these pics show the change it made. Its also gas and solvent safe as well as hi-temp approved.

Yes, thank you Vanna........... Maybe some fresh air for Cam.


Lastly for the evening, we finally got the gaudy original license cluster off.
We want this look.


Cam has an idea, that using some simple "L" shaped brackets from his work, we can use the original tag flange removed from an FZ6 and attach it to the threaded brass inserts that are already in our tail fender, leftover from removing the tag light. We will let you know how this goes.

[StargazrgirL]

This bike is going to look really good by the time it's all over with!  

Can't wait to work on it more..

Christa  
AKA: The wife

[BakonMoto]

I'll bet this will likely be one of those projects that you guys will take a nostalgic view of many years down the road. Some of the most epic and memorable wrenching sessions I was ever involved in were the ones that were the most frustrating and rewarding to me and my buddies with our junker Brit cars more than 30 years ago, and usually involved a lot of cussing  , mashed fingers, tossed and lost wrenches  , close calls with heavy metal hanging by cheap block'n'tackle from a marginal roof truss , judicious application of adult beverage , high-fives and cheers when the engines actually started back up  , repeated toasts to Morris Garages, Austin Healey, MOWOG,  or anyone else to whom we could think of raising our mugs (even Lucas Electrics)  , and genuine camaraderie  .

  Of course, back in them days our beer didn't come with lime in it; we had to plant, grow, fertilize and harvest our own lime trees, toiling night and day in the hot sun  , walking 10 miles to school every day, up-hill both ways...

... and the kids these days think they have it tough...  

Bryan

[Gvilleracer]

Its funny you mention it, Im really more of lager & dark fan.

But this lime stuff is actually very refreshing!
Very Jimmey Buffet feeling while you sit back and relax.
They are very light though, so you need a few......

[airvent]

Great write up and pictures! 

Keep up the good work 

[Gvilleracer]

Great write up and pictures!  

Keep up the good work  

Hey, I'm learning from the best.
I read your thread before even starting my project.

PS, how do you like the Seal savers.
I bought Dirt skins and stock boots and havn't decided which to use yet.

[SLO-KLR]

Any neoprene boot will create stiction, something you don't want.