Back to the Future

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IanB

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TroUtman_888 wrote:
Wow!!! You have taken what I've always thought the ugliest of the duals and made it into a hot looking bike. Nice work. You may have a newbusiness from that fairing. Get it patented soon.:hb:

Sadly, patenting something like this is not on. On the other hand, although one can copy 'anything', this mold is split in 3 places so it's quite complex to copy.

Anyway, I do plan to produce the fairing kit (with or without the dash) in OEM colours after I've thoroughly tested this prototype on and off road:tup:

Thanks for your kind comments

Cheers Ian:clap:
 
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jaydee

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Great job man. I have to agree, I personally feel the 08's look but-ugly and this is far more exciting to look at. I've actually just began my own project fairing over the last few days - I'll post some pics when I finally get all this cardboard taped down haha.

again - very nice...
 
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IanB

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Good luck with the fairing:clap:, looks like I've started something!

I got a good few 'on road' hours on the bike today and will post up a report and pics tomorrow:tup:

Cheers Ian:hb:
 
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IanB

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And so to the riding, which I guess is what it wasall about:tup:

I was aprehensive about trying the bike after a year and so many changes, so here is a view on all the major parts:

Forks/Steering/Brakes

The bike sits higher, both front and back now and I sense that it steers a bit quicker than stock. However there were no stability issues right up to 160ks. On Road there is really no major difference from stock (Read on for 'off' road). Not surprisingly, the front brakes were a big improvement with the 2 pot Nissins, but stillnothing to write home aboutagainst more modern stuff. There is still plenty of dive when you yank on the lever !

One particular benefit that I wasn't expecting, was the much reduced vibration through the bars:tup:. I put this down to the rubber mounted risers and the protaper bars.

The Fairing

Certainly from an on-road point of view, this is the biggest difference. The wind protection is fabulous, with cruise speeds of 130-140 absolutely effortless. The 'ram air' effect that I was looking for under the screen has eliminated any buffeting and transforms this bikes 'long haul' capabilities on the highway.

The looks will alway's be a matter of opinion, but I have been totally choughed at the number of 'non biking' people who have made comments at gas stations etc. One woman said 'it looks so futuristic' !!:hr:. I'm not sure anyone on a KLR has ever had that said to them , have they? Anyway, I'm pleased and I'm in discussions at the moment with regard to selling the fairing as a kit for the stock bikes.

Instruments

I sort of 'fell into' redoing the instruments. I wanted a better dash arrangement for additional instruments and changing the forks and triple clamps (holding the stock clocks) meant I had to look at something. The digital instrument from Acewell is great and works flawlessly in every respect. It is totally accurate, so I must be the first person on a KLR to actually know how fast I'm going!:tup:

Off road

I asked Sheldon if he would test ride the bike off road, not just so I could take pictures, but mainly because he's a much better rider than me and could 'extend the envelope' a bit! He didn't disappoint!!:wi:

A picture saves a thousand words, so look on !!

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Good job I changes the Rims as well!!!

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He's doing about 125 here!!



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Has he finished yet ?:wi:



Believe it or not, when the front wheel was on the ground the forks tracked superbely over the moderate pot holes, which only egged him on more!! When he finally got off, he said " that's not like any KLR I've ridden !!!"

And that, people, is excactly why I started it in the first place:tup:!!!!!!!!!!!!

See you and it at the show - Cheers Ian:hb:

 

Yak_KLR650

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You're the man!:tup: That looks great. Let me know when the kit is available - I want one!:clap:

Congratulations on a successful project.

Doug.
 

JavaJude

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[align=center]:dr:WOW ! ! ! ! ! :dr:[/align]
[align=left]That looks like it was too much fun. Good job on the test ride Sheldon (call me in the morning and tell me what it was really like :p). [/align]
[align=left]Great photos Ian. Thank you for the updates. Now to work on the display for the M/C Show to best showcase this machine. For those of you attending the Vancouver Motorcycle Show on Jan 25-28, Ian's bike will be on display in our DSBC booth. [/align]
[align=left]Also Ian, your KLR XS decal is :tup:. Well done!!!![/align]
[align=left]-Judy-[/align]
[align=left][/align]
[align=center][/align]
 
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ElChupacabra

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Meca Systems make a kit for the KTM EXCs (watch Jonah Street on this year's Dakar) Here's an idea of US prices for their kits to help you with your business plan and pricing.

rallybike.jpg





[line]




Ref. DescriptionPrice





[align=left]KR105 20 L 2-element front plastic tanks including supports and fiberglass trim 1,475.00 $[/align]



[align=left]KR61 Front petrol flexible hose kit with fuel pump 262.50 $[/align]



[align=left]KR66 Fairing top center (fiberglass, untreated, no Gel Coat) 330.00 $[/align]



[align=left]KR67 Fairing right side (fiberglass, untreated, no Gel Coat) 343.75 $[/align]



[align=left]KR68 Fairing left side (fiberglass, untreated, no Gel Coat) 343.75 $[/align]



[align=left]KR50 Instrument support holder: Stainless steel frame clamp. Aluminium arc. Roller support T (including threaded fasteners and spacers) 435.00 $[/align]



[align=left]KR70 Fairing and lens support bar 227.50 $[/align]



[align=left]KR71 Double headlamp lens (no bulb) 170.00 $[/align]



[align=left]KR71A Bulbs for headlamp (pair) 54.88 $[/align]



[align=left]KR92 Lexan headlamp guard 43.75 $[/align]


[align=left]
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[/align]


[align=left][/align]


[align=left]Awesome job Ian!!:tup:[/align]


[align=left][/align]


[align=left]Paul[/align]
 
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dooveman

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So just to be devil's advocate, cause I actually like the fairing but need to ask:

- The big diff is that the front wheel mud guard no longer tracks the front wheel when cornering. During your dirt trials, did you see excessive spray when turning? Also you lost the back of the front mud guard which exposes the rad and triple tree and instruments to mud.

By the way I just looked at Kawasaki canada and here is a link to the new 2008 KLR:
http://www.kawasaki.ca/flx/model.php?s=3&l=en&m=1062

The green looks nicest. Although I still like your fairing more although I'm not sure about fixing it to the mud guard which is why I asked.

Brian
 

DRuZer

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It looks awsome, Ian. I always liked the KLR, but couldn't get over the crappy little forks used to support its heft. Even the '08 forks look inadequate, like something out of the 70's.

I too wonder about the fixed front fender, but time will tell and I suspect that you will conjure up a suitably well appointed solution should the need arise.

Fantastic! I look forward to wheeling it up onto (or off of) the display at the bike show!
Cheers,
Guy
 
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IanB

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You're quite right to point out the issue over the mudguard guy's and I knew from the get go that this would have to be overcome. So, I thought I would see how bad it was and where the main overspray would occur first.

As of today, I have made a mudguard that fits under the triple clamp and turns with the wheel. It extends down as far asa normal guards at the back, but the front, only extends about 6" before the main fixed fender takes over. I haven't trimmed it to its final size yet, but it is much thinner in sideways profile so that it does it's job without spoiling the looks. The front bit doesn't show at all as it tucks up under the fixed fairing.:tup:

There doesn't seem to be an excessive amount flicking back into the headlight from the front. I guess this is because the wheel is always pretty much in alignment with the fixed fairing when at any sort of speed (hopefully!!).

I should be able to try all this out before the show and the bike will have it fitted then.:hb:Ian
 
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dooveman

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Yeah, similar to the BMW 1200gs. Makes sense.

And how does the f650 dakar do it? Similar look to yours and similar double fender idea. But it looks like the front also tracks the wheel. It is seperate with a cut perpendicular to the forks. Ofcourse now its a 3 piece design, which adds complexity.

http://www.bmbikes.co.uk/photos/photophotos/2004F650GSDakar Bluemet-Whitealu.jpg

Can you explain the windshield design? You said that it reduced buffeting. Is it the space between the windshield and the fairing? Or the height/ angle of the windshield?

Man I wish I had access to the equipment you do. Looks like alot of fun.

Oh and I realized that one issue with the 2008 is that it won't support the oversized tank anymore. I guess the military will have to rip that fairing off and get a custom one. Hey there you go. You could design a 2008 fairing that supports the oversized tank:tup:

Brian
 
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IanB

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dooveman wrote:
Yeah, similar to the BMW 1200gs. Makes sense.

And how does the f650 dakar do it? Similar look to yours and similar double fender idea. But it looks like the front also tracks the wheel. It is seperate with a cut perpendicular to the forks. Ofcourse now its a 3 piece design, which adds complexity.

http://www.bmbikes.co.uk/photos/photophotos/2004F650GSDakar%20Bluemet-Whitealu.jpg

Can you explain the windshield design? You said that it reduced buffeting. Is it the space between the windshield and the fairing? Or the height/ angle of the windshield?

Man I wish I had access to the equipment you do. Looks like alot of fun.

Oh and I realized that one issue with the 2008 is that it won't support the oversized tank anymore. I guess the military will have to rip that fairing off and get a custom one. Hey there you go. You could design a 2008 fairing that supports the oversized tank:tup:

Brian

The part thatI have made for the mudguard looks pretty similar to the BMW 650, although I haven't studied it closely. Hopefully it'll do the job.

The screen fits on top of two vertical 'bars' that are part of the fairing which act as the sides of a 'scoop'. This sets the screen about 3/4" in front of the fairing so now you have a rectangular slot about 5"x3/4". The ram air effect from the front of the fairing almost doubles the airspeed coming up the back of the screen through the slot. So this jet of air heading upwards carries all the turbulant air that is coming off the screen and sends it over your head.

So, the faster you go, the greater the jet. In effect, it's a bit like driving with an invisible screen in front of you. I made it slide down out of the way so it is out of my vision off road, although the jet effect is still working.

That':tup:s the theory anyway !!
 
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dooveman

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That's pretty cool. I'll be at the booth at the show. Can't wait to check it out.
Brian
 
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Carg

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That fairing is really sweet. :clap:

Just so you know, I for one would be interested in just the fairing itself.

I'm from http://www.advrider.com and someone from here posted a link.

There was a guy over at those forums who also had a molding project for a fairing on a KLR, which he didn't want to duplicate/market, much to our frustration.

So anyways, the KLR people do want something like this!!!
 
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IanB

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First off, many thanks for all the kind comments about the bike from all of you who visited the DSBC stand at the Vancouver Bike show:clap:

A number of you have emailed or called, asking where things stand regarding availability of the fairing.:wi:

So here is an update of the issues I need to solve, before it's available.

One of the main issues on my mind was whether the whole thing should be produced in plastic instead of Fibreglass from a cost/durability point of view. I can now confirm that the cost of producing this in plastic would be hugely expensive, unless the numbers are vast. I am now able to concentrate on creating acomposite materiallayupprogram that will provide the durability necessary for life on a typical KLR :hr:.

(A number of people have commented " don't bother with the testing proceedure, because Kawasaki obviously havn't bothered on the '08 !" - No comment)

Two aspects of the design need to be improved. Firstly, I wanted the recess in front of the headlight to be able to act as a 'tray' to accomodate a typical spare tube bag and at the moment it narrows down too much at the front. Secondly, when I gave it a thorough off road workout last week, I noticed that I was getting too much mud coming over the front of the fender and back on the headlight. You always expect to get some on very dirty ride, but this was too much. This will need to be altered as well. Lastly, on the design, I would like to make a 'dash' design available, that will sit above the stock clocks in the much larger space available behind the taller screen to provide more instrument space. This is something I didn't need to address on mine, because the clocks (along with the forks) had been changed and replaced with a digital unit.

Next will be the colours. I am guessing that most owners will not want to paint their bikes just because they want the fairing (feedback on this woud be welcome), so I need to get material matched to all of the coloursin whichthe bike has been produced in since, say, 1999. Additionaly, I will also need to source a plastics setup that can produce the adjustable windscreen part and source the fasteners.

Lastly, I have to decide how this should be marketed. My initial approachis to market the whole package via a set up already dealing with KLR bits and just be the 'producer'. However, it may be that this unit does not create enough interest for them to be bothered with it, so I'll have to do it through my own company.

Either way, for those that are interested, by the time all this has been done and the 'destruction' testing has bee carried out, you can expect it to be available by the end of April. Cost still has to be finalised, but expect it to be between $CAN350- 450 complete.

Cheers Ian:hb:
 
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IanB

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It seems ages since the last post, but finally the pre-production fairing has been made and it should address the outstanding issues mentioned above:tup:

Tony Dathan (PocoRed) kindly offered himself and his stock KLR to test out the unit :clap:and here are some initial pics from the 'fitting' session.



Out she comes ! The coulourmatch isn't quite right yet.



Tony goes for 'test flight'



Note the adjustable screen in the 'down' position' and the slots in the deeper recess for allowing air in behind the fairing to reduce the vacuum effect of the larger frontal area.

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88IMG_1676.JPG


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88IMG_1682.JPG


Loads of room here for extra dash and instruments. Somebody else can work out how !!

So, Tony will go on and use this giving me feedback on what's good and what's not so good while I get the whole thing ready for production. At the moment, we're still in shape to make it available at the end of the month:tup:

Cheers Ian
 
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dooveman

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:shock: <- That is my face when I looked at these pics. That is amazing Ian! The red is so nice! Way to go. Nice to see this project hit such a home run.

Are his instruments still attached to his triple tree? And it doesn't hit the fairing? So the fairing has the same space as the old one but taller? Just wondering how more instruments could be added. To the fairing? You could mount something to the bottom of the shield slots. A 15"inch TV for the Canucks playoffs:)

Very nice Ian.
Brian
 
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Poco Red

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Brian I've just zipped my volt meter to the standard gages for now untill I make a new dask to attach to. The new fairing is a couple of inches forward of where the stock one was and taller so you can have a complete gage cluster if you wish. don't know about a 15" but certainly an 8"! :tup:If you want a pic from a certain angle let me know and I'll send one for you. If you want to hook up in the lower mainland to check it out, send me a PM!

:clap:
 
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IanB

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Hey Tony, did you try the fairing in the wet over the weekend ?:tup:
 
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