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Old 18 Sep 2007
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Join Date: Sep 2007
Location: Boulder, CO, USA
Posts: 182
Durability Upgrades for a KLR-650?

I am planning on spending a few years riding the world on my (2005) KLR 650 (inspired in no small part by this site! ) and am looking to pick the brains of all you who have picked this same bike for similar trips.

I'm finding more ideas on what can be upgraded than I can shake a stick at...but mostly from pre-trip planning (Such as this post, it occurs to me ). I'm hoping mostly for feedback from those who have been on a KLR for long who can give input on what was a good idea to upgrade, what was a waste of money/weight, and what was missed that should have been changed.

VITAL CHANGES
  • doohikey: No need to elaborate here
  • Stainless Steel Break Line (Front): Increases safety in emergency stops
  • Rear Master-Cylinder Guard: Protect the cheap plastic from a crash
  • Wiring Hardness Upgrade: Increased headlight output
  • Carb Vent Kit: Needed for water crossings
  • Low-profile magnetic oil drain plug: In case of narrow misses with a rock & trapping engine debris.
  • Subframe Bolt Upgrade: Don't want these to sheer off from vibration!
  • Radiator Fan Blade (metal): Stock plastic blade is too easily damaged
  • Serrated foot pegs: For water & mud. Dual Star or IMS?
  • Enlarged side-stand foot: Stock is too small for soft surfaces
  • Folding Shift Lever: Less chance it'll break. MSR or IMS brand?
  • Acerbis Rally Pro hand guards & spoilers: Better protection for controls than stock
  • Sealed Bearings: Increases longevity
  • LED flashing break light: Type that only flashes for a short time. Increases visibility & decreases power use & eliminates bulb use.
  • Progressive Springs (rear): Stock is insufficient for long-term heavy loads.
CONVENIENCE UPGRADES
  • ATO fuse upgrade/relocation kit: More durable & easier to reach
  • Progressive Springs (front): Better overall performance & longevity
  • Billet Oil Filler Cap: Needs wrench to open - prevents people from putting in things they shouldn't. For peace of mind mostly.
  • Break system speed bleeders: For ease of maintenance
  • ScottOiler Dual Injector: Improved chain life & ease of maintenance
  • LED Turn Signals: More durable than standard bulbs.
  • Stainless Steel Oil Filter: Because a non-reusable filter may be hard to find.
REJECTED FOR WEIGHT, EXPENSE, ETC.
  • Stainless Steel Break Line (Rear): I can already lock up the rear break at will
  • Centerstand: Not worth the weight. Use a length of tube to raise either tire & double as other uses.
UNKNOWN - FEEDBACK ON USEFULNESS?
  • Drive Chain with a Master Link: Am I correct that the stock chain has no master link? Should I use an X-ring or O-ring chain? Clip or Rivet style master link?
  • HID Headlight: Need to find either a full HID headlight replacement (not just bulb) or HID driving lights.
  • Heated Grips: Is there enough need to justify the cost & power usage?
  • IMS Fuel Tank: Provides longer range & radiator protection, however cap does not lock.
  • Happy-Trails Nerf Bars: Protection worth the weight? Not for use with IMS tank.
  • Radiator & Reservoir Guards: Alternative to Nerf Bars for less weight (or if using IMS tank).
  • Fork Brace: I've never felt the need. What benefit would it provide?
  • Water Pump Guard: Is this worth the cost?
  • Skid Plate: Is the added protection really worth the extra weight?
  • Locking Axel Nuts: Will the self-locking mechanism hold up throughout the trip? If so, better than cotter pins or hitch pins.
  • Locking rear-axle alignment nuts: Undecided if better or worse than stock dual-nut system
There you have it! Fire away with your suggestions, alterations, additions, rants, and raves. Please give your justification for each suggested change!
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Traveling The World Since: 2011
Blog: The Seductive Life (General Travel)

Last edited by othalan; 24 Sep 2007 at 05:04.
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