When I bought the KLR back in July Josh included the old tank shrouds with the bike. The only problem is they had been torn off a few times and were in pretty bad shape. This weekend I finally got around to mounting them back to the bike.
Read more below.
I’ve always been a bit annoyed about how incomplete the bike looked without the tank shrouds but never actually gotten around to re-attaching them. One day while riding home an idea struck for a fairly clean way to attach them without having to resort to safety wire or duct tape.
The early model KLR tank shrouds are held by a peg that snaps into a rubber grommet on the tank and two tabs, to attach you simply pop the peg into the grommet and thread screws into the tabs. It’s quite common to tear these tank shrouds off in a crash and this bike was no exception (The original owner wrecked it in the desert).
I started by cutting off all the surviving protrusions and then smoothing the material.
Then I drilled holes for the new method of attaching the shrouds.
I am replacing the peg with a carriage bolt, using jam nuts and washers to space things out properly. I used a utility knife to square off the 3/8″ holes in the shroud then shortened the square neck of the bolt to the thickness of the shroud, while I was at it I also ground the markings off the carriage bolt heads.
Then it was time to start cutting metal! Instead of having sheet metal tabs from the radiator and overflow tank bridge a gap over to the tank shroud I decided to make L brackets that attach directly to the tank shroud with rivets and then bolt to the radiator and overflow tank.
Once all the materials were ready I mocked up a test fit prior to painting.
The KLR being a big single it has a tendency to shed fasteners. To fight this I used red Lock Tite on both the jam nuts per carriage bolt. The last nut, the one that actually holds the piece on, is a nylock nut.
It almost looks factory with the black rivets and carriage bolt. I was a bit impatient to get everything together so the bolt didn’t have enough time to fully dry, I’ll go back and touch the paint up later. Click to enlarge.
That was the last bit of crash damage to repair on the bike, now that it’s back to 100% it’s time to focus on putting better stuff on it. To take them off all I need is a 14mm, 8mm, and 10mm wrenches, all of which are tools included in the OEM tool kit I carry on the bike.