hey Ian

I have two little voltmeters that work. Thanx, you saved me buying a new one on the road.

the important spare parts, listed from the comments on this thread, are:

1. Clutch cable(s)
2. Fork seals
3. Tire tubes and good patch kit
4. Fuses
5. bulbs(headlight, 1 or 2 signals, brake light)
6. Brake and clutch levers - consider bark busters instead (determine importance by time off road?)
7. Throttle cable - rare to break?? (pull one only)
8. some bolts/nuts (selection of M6, M8 and M10)
9. two spare master links and short length of chain
10. spare wire and electrical connectors.
11. Brake pads
12. Hitch pins
13. valve cores
14. prepared air filter

Part maintanance, retainment, fixes, diagnostics

• JB Weld RTV silicone
• volt meter
• blue locktite
• small WD40
• chain lube
• cable ties
• electical tape
• duct tape
• separator funnel for bad fuel(depending on where you are going)

Any ideas for additions to this list would be appreciated. any insight for omission, unimportance or importance of a part. Any redundancies? The insights will be used for prioritizing

Troy

THe third year I had my 2000 KLR the rad fan motor packed it in at Winnipeg.No problem if I kept a pace where travel speed moved enough cooling air across rad. A day later in Brandon the Kaw dealer had a nearly new fan for me from a wrecked new bike. Luck, but no need to carry a spare motor. Ditto when a clutch cable hung onto 3 strands while I found the Kaw dealer in Monterrey Mexico,; cooked old battery in Colima, found exact replacement there. Now I do consider getting a spare cable though, do carry replacement brake pads.
Point is, if you are in area of large cities you can find replacements- if you devote the time to search .
Now as for my shifter detent spring- I was just being frugal and lazy. it broke on a Teusday afternoon late in Ixtlan de Juarez,Oax in the middle of the mountains, no nearby Kaw dealers. The spring loss did not affect my mobility. Next morning the road Mex 175 north was a great swoopy mountain road for 100km and second gear was often too fast! Hairpins! scenery!Made it to Veracruz before dark. If I did find a Kaw dealer there they would most likely need to order in the part- a day or 2 or 4 wait. Nope , just kept on riding and every day I covered as many km as is normal in Mexico for me even with all 6 gears, around 300km to 375km
Just kept the engine running at around 4800rpm which my overly optimistic speedo suggested was 75 to 80 km/h but probably more like
65km/h.
Sunday evening I was in Lufkin TX.Monday morning the Kaw dealer there had---- no spring in stock, could have one next day sometime. No thanx.
But it was spring weather, the TX wildflowers in full bloom on roadsides.
In the US I did even more km per day, a couple even in the 490s.And all the while I was breaking out in a smile every few minutes enjoying the ride with my visor up. To Ontario home it was 4785 km in 11 days. In other words for my riding style I had experienced no delay in Mexico and in the US I had doubled my time - because I was enjoying the ride by taking backroads and parkways, so actually no delay, just a different ride.

__________________
http://advrider.com/index.php?thread....207964/page-5 then scroll down to post #93

Sjoerd,

It's small, it's cheap, it isn't totally necessary, but might be nice to have.

4785 divided by 65 equals 73 hours divided by 11 equals about 6 and half hours of secound gear driving a day though the daisies.

Interesting how again the adventure is enhanced by having a less than perfect bike.....again running it in secound gear for 11 days probably led to some awesome scenery and, indeed, you did slow down to smell the flowers. Another good story. However, i think that this small piece needs to be added to the list.

the important spare parts, listed from the comments on this thread, are:

1. Clutch cable(s)
2. Fork seals
3. Tire tubes and good patch kit
4. Fuses
5. bulbs(headlight, 1 or 2 signals, brake light)
6. Brake and clutch levers - consider bark busters instead (determine importance by time off road?)
7. Throttle cable - rare to break?? (pull one only)
8. some bolts/nuts (selection of M6, M8 and M10)
9. two spare master links and short length of chain
10. spare wire and electrical connectors.
11. Brake pads
12. Hitch pins
13. valve cores
14. prepared air filter
15. shifter
16. shifter detent spring

Part maintanance, retainment, fixes, diagnostics

• JB Weld RTV silicone
• volt meter
• blue locktite
• small WD40
• chain lube
• cable ties
• electical tape
• duct tape
• separator funnel for bad fuel(depending on where you are going)

Any ideas for additions to this list would be appreciated. any insight for omission, unimportance or importance of a part. Any redundancies? The insights will be used for prioritizing

Troy

Actually if you have a well used high km motorcycle it would make sense to replace the spring before it breaks of old age and metal fatigue BEFORE starting on a very long trip.You can't get away with replacing only that spring if you are going to do a proper repair.
When mine broke it was at 104500 km and 10 years old.At that age it would be silly to take the engine side apart and not rebuild the water pump, replace all exposed and removed aged O-rings and crankcase oil seal and the case gaskets and clean out the oil pump strainer.
It is preventive maintenance and would save somebody with less patience a bit of frustration on the road. Travelling alone has its advantage- no need to hurry repairs to catch up to an impatient group trying to prove their studly riding prowess to others, itinerary and route can be changed on a whim

__________________
http://advrider.com/index.php?thread....207964/page-5 then scroll down to post #93

I've ridden with lots of KLRs through the years. Never RTW but in some very remote places. About the only spare parts needed other than tubes and patches were clutch cables and fuses.
The only electrical problems on my 03 KLR (30,000 miles) have been low water in the battery and a failed starter solenoid.

I have changed my axle and chain adjust nuts to a self locking type. No clevis pins needed. I also use a prevailing torque nut on the primary. It makes changing the counter shaft sprocket a breeze.

My fault totally for not checking what was handed over the counter, but I just found out that the brake pads I brought in Perth Australia don't fit the KLR - Yep, now half way through Peru.

So my addition to the list would be to make sure that what ever bike specific parts you buy / take are actually for your bike. Seems obvious and I feel a real numpty for not doing it, but take them out of the packet and double check them.

Signed silly old fool

__________________

This is a list of potential spares that i made based on my own experience and what i learned from others.

Last week, my stator just died out of the blue while i was idling at a red light. my bike has 50k miles and runs like a clock.

lucky i was just a couple of miles from home, and i had a spare stator in my garage (the faulty part was the exciter coil, which means no sparks!!

In the past i had a water pump seal failure, drive shaft oil seal leak, in addition to the usual bulbs, clutch cables, shifter, levers etc.

I know some people who broke the carb membrane, and blew their shock.

- bulbs
- fuses
- brake pads
- clutch cable
- levers
- shifter
- sparkplug
- chain master link
- rear brake pedal mounting bracket (known to break easily)
- water pump mechanical seal
- drive shaft oil seal
- shifter oil seal
- fork seals
- carb membrane
- wheel ball bearings (there are 4 different sizes)
- CDI unit & diode
- voltage rectifier
- Stator
- Rear shock (with spring removed)

it is always annoying to get completely stuck and to have to wait days for a replacement part to be shipped.