KLX 650 C Conversion to Rally Rig

we then proceed to install a rally kit given to us by a friend and as you can see it has a liquid tank, a toolbox and a carbon-kevlar protective plate, really beautiful!

now get to the main part of this project
we lay the bike down on its side to open the cover clutch

To install a kickstart we will also need to replace the brake pedal

the pedal of the C version obstructs and blocks where the kicks start normally goes in the R version at the exit hole of the crank shaft

Once case open, we carefully put all the extracted screws in order we also unscrew them by loosening them in sequence

then unscrew the nut that holds the clutch basket

we will need an air gun to do this

clutch basket removed

a quick comparison of the clutch baskets of a C klx and R klx shows how the R version has teeth for the kick start to catch whereas the C model does not

the kit for the complete conversion to kick start






we install the kick start and we make sure the seal is in place to avoid any leakage

this is what the final product looks like

dashboard

a real adventure tourer

nice project. could you list the parts needed to add the kickstart? I have been wanting to do this for some time and never could figure out how to search the yahoo site for info.

thank you for bringing that to my attention. I just realized I forgot to post that part lol

here is a picture of the kit:

just to elaborate a little bit about this kick start conversion. It is something I truly like and feel like it must be made available. This reliance on battery to start I find silly and is mostly directed to urban motorcycling. (mall crawlers?! sorry for the jeep joke I couldn't resist )

a couple years ago I was on a different bike (german one) with electric start only and it refused to start in the middle of nowhere Africa....I couldnt' get it to start I pushed, I tried jump starting it, it was just dumb... In that remote area the locals had nothing to sell, only option in the closest "big town" was an auto-part store who offered to sell me a big a$$ car battery. it was a costly problem took significant time and money from that trip considering the logistics of getting to Africa form here. so yeah...sorry for the rant lol

anyway I like kick start, kudos to LC4 ktms for having kick start. I'm always looking for and reading about kick start conversions.

this one seems to be fairly manageable. Part wise, I think your best bet is to find parts from a KLX R somewhere and do it. as indicated in the pics it should be plug and play. good luck let me know if you have questions. greetings to the beautiful PNW!

Flyingwheel wrote:

this part here does not necessarily need the air gun/compressor, I did it with a regular socket wrench combination. you just have to lock the clutch (putting it in gear and someone step on the rear brake)

what I like about this entire project is the cost, it was very cost effective nothing insane that an average joe can't do.

I see projects elsewhere where people go insane, I prefer projects where you stay married afterwards and not sleep in the dog house


to me the challenge is not to build the most impressive stuff. The trick is to do the most interesting stuff with the lowest cost and perhaps recycling what you already have.

Hey Flyingwheel,

What rear fender are you using?

Thanks,

Kurt138