Hi AVID and oldrider,

I had a 2003 KLR with 5000 miles on it, did a trip around the states and mexico and left 21,000 miles on it. 70% good roads, 30% dirt and bad roads.
Problems/Repairs: bolts in rear rack loosened and snapped, front sprocket and chain severley worn around 11,000 (maybe from rider slackness), 2 rear tyres and 1 front, 1 set of brakes, speedometer cable died, fuel cap started to leak out top (when on side), bike got a little smashed up as I used soft panniers and had no radiator guards when i dropped it, had serious wind fatigue and sore neck from small stock windshield across the great plains.

Currently in Colombia on my way to Argentina from Alaska on a 2012 KLR, 80% good roads 20% dirt and bad roads. 15,500 miles on the clock so far.
Problems/Repairs: 2 rear tyres and 1 front, 1 headlight blown, 2 main frame bolts loosened and fell out, front sprocket and chain severley worn around 11,000 (maybe from rider slackness again) rear sprocket was perfect, rear wheel just starting to wobble bad (needs balancing), temperature guage stopped working, uses fair bit of oil when doing above 65 mph, new front and rear brakes at 8000 and due for a new set now. Air filter gets pretty filthy especially south of the border in the rainy areas, got serious pins and needles in fingers and toes from stock hand grips and pedals rubbers so I put a double thickness of the pillow grips and its a much smoother ride. Seat was too high so I pulled it apart cut off an inch of foam and now I'm closer to the ground.

Advice from mechanics/old hands along the way: spokes can loosen after a while, check valve clearances - checked mine at 8000 and were in specs (will check again in next few days), check oil levels after long rides, mineral and synthetic oils dont mix too well, replace the chain/front and rear sprocket around 10-15000miles as it will probably be shot around then anyway, dont use engine oil as a chain lube as when the chain heats up it wont bind too well and will flick off

Tips from my recent ride: some stuff hard to get in some places e.g synthetic oils/ air filter oil and good chain lube, take at least a spare front sprocket so when it needs doing you dont have to wait for weeks to have it shipped. For some reason even the major dealers I've encountered dont stock them. If your really keen you could take a fresh chain as well as the front sprocket and you'll have at least a spare chain if you snap or destroy it, WD40 along with a plastic bristle brush to clean your chain, happy trails front crash bars, moose handguards rear rack and pelican cases have saved my bike and my bacon twice now. Centre stand a must for tyre changing, proper chain maintenance and bead braking. High windshield good on open roads where you can go fast but not real good in tropics when you need that air flow and are going much slower on windy roads.

Have done everything pretty much to the Kawi maintenance specs and the KLR has not really ever let me down, and will do the major 15000 mile service in next few days, so will post any other issues that have arisen.

cheers