KLR 600 and 650
The most important: The doohickey is the same means you can use aftermarket ones on th 600. Want to say that I did not have any of the later version KLR doohickeys (balancer chain idler lever) packing up so far but I had a snapped idler spring recently (larger dia. later version).
Very little need to do a lot on the bike IMHO. The KLR 600 has the same crappy front brake as the current KL650A. The late 90's European model KL650C was lots better and you can use the C caliper on A or 600 forks and discs. Not that it really matters on an overland bike.
The KL650 C has a 41 mm fork as well as my (South African official KMSA) 2004 and 2005 KL650A's. The KLR600 has a 38mm fork and this apparently was also used on the newer models KL650A in other countries (?)
What in detail do you want to get for the bike?
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