KLR 650 Modifications

[R_W]

Originally Posted by greenfreak

I'm trying to install an odyssey battery on my klr and am having difficulties findind a way to secure the battery in place. Dual star claims slight mods are required to make the install and am either dumb or stupid as I can not see how or what materials I should use to hold the battery in the air box compaertment. Any suggestions?

Sideways, negative terminal down. Only use the metal bracket, not the plastic battery cover. You will need to make a 6" extension for that small ground cable, just bullet male and female. I shimmed the side of the box w/ some foam to keep the battery tight.

My only complaint has been tires, the scorpion AT was my least favorite-go figure. I got crap mileage out of them, I like the ST much better as a road tire.

and my un-do's have been windshield, fender, and handguards trying to find the combination that minimizes turbulence and maximizes protecton.

[KSJEEPER]

Happy Trails Hway Bar / Engine Guard, with stock KLR pegs mounted on Bar.
Acerbis Motard front fender (lessened wind gust problems on hway)
Corbin Flat
Seal Savers (long)
Ebay Fork Brace (the $80 one)
Aluminum Skid Plate
JC Whitney large top trunk
Bar end vibe dampers
Bar risers
Vista Cruise
320mm rotor kit, with stainless line


That's all I can think of...

[MNMike]

Came with:
+4 Windscreen
OEM Tank Bag

Now has:
Relocated License Plate
+9 windscreen
Optronics QH-61CW Off Road Driving lights w/Relay
Moose 'Bark Busters' with Large protectors
Scott Fusion Grips
Mirror Vibration Isolators
Givi Monokey Mount Rack on
Happy Trails Rack Extender
Givi E45NJ Topcase
Progressive 420 Series Shock Spring
Progressive Fork Springs
Garmin GPS mount
Metzeler Enduro3 Sahara tires
12v Accessory Socket
Sylvania SilverStar Headlight bulb
Magnetic Drain Plug

[Twin headlight Ernie]

I've done a few mods to my bike that no one else seems to have done. One thing I did that everyone seems to like is to modify my clutch arm. ( the one on the engine). I cut the arm in half and added about 3/4" of steel strap in between the two halves. I then welded the piece in and ground the welds down smooth so they can't be seen. I've never had anyone spot the mod without me pointing it out to them. The mod lightens up the clutch feel and is easier to feather on hills and such. I did a simular mod on my Jeep years ago. I welded a extra long bracket on the bell crank to compensate for the heavy clutch. I'm a engineer and a good TIG welder and just can't seem to leave anything well enough alone. I'll try to get a good picture. I bet Gadget Boy is just giddy to see it. If anyone is interested I'd be willing to do the mod for them. I have a spare lever I could mod first and exchange. Ernie

[R_W]

Originally Posted by Twin headlight Ernie

I've done a few mods to my bike that no one else seems to have done. One thing I did that everyone seems to like is to modify my clutch arm. ( the one on the engine). I cut the arm in half and added about 3/4" of steel strap in between the two halves. I then welded the piece in and ground the welds down smooth so they can't be seen. I've never had anyone spot the mod without me pointing it out to them. The mod lightens up the clutch feel and is easier to feather on hills and such. I did a simular mod on my Jeep years ago. I welded a extra long bracket on the bell crank to compensate for the heavy clutch. I'm a engineer and a good TIG welder and just can't seem to leave anything well enough alone. I'll try to get a good picture. I bet Gadget Boy is just giddy to see it. If anyone is interested I'd be willing to do the mod for them. I have a spare lever I could mod first and exchange. Ernie

Now that is cool.

[Right Turn Clyde]

Originally Posted by nooner818

For me, doing the mods on my motorcycle is just part of the hobby. I would have probably done the same thing no matter what motorcycle I bought, needed or not. I have always liked tinkering and trying to make something work better for me. It's not about the money, it's just something that I enjoy.

It's the journey, not the destination.

nooner, I'm with ya. I like the unique bike you get with all the tinkering. But the whole "you'll save money" with a KLR gets folks thinking it's all good. Truth is, the huge list of farkle means not just plenty of customizing, but a virtual pipe from your wallet to _______ (name your vendor). That's fine, but for those of us with weak willpower and strong tinkering bents it spells: $$$$$$$$

…course, could you imagine the bill for doing the same when Touratech, etc is where you buy your bits vs. klr650.com?

[Twin headlight Ernie]

I though of another mod. I'm a retired musician/guitar player. They make a item for guitars called a strap lock. Its a chrome quick release dodad where one half mounts to the guitar and the other half mounts to the strap. When connected it keeps your high dollar Stratocaster from hitting the stage floor. I mounted the half that mounts to the guitar on the frame of the bike between the seat and the tank on both sides. The other half gets mounted to the straps on the tank bag. This half has a pull to release knob on it. It makes taking the tank bag on and off a lot easier. No more fumbling with D rings around the frame. I believe the name brand I use are made by the Schaller Co. They make guitar hardware. I'd bet they have a web site to check them out. This is what I like to call cross/over engineering. Ernie

[cobalt60]

Ok, yes a KLR will cost you less....but ther are so many accessories and extras it will potentially cost you more...So Why a KLR?? In my experiences most KLR riders are cheap, but are also tinkerers and do it your selfers. Yes you could buy a KTM adventure, but you would have no money left over for extras like luggage, pipes, guards, etc....

A KLR rider buys the KLR, can afford the initial price or payment, but will...over time...accumulate aftermarket parts and occupy his or her spare time modifying or installing the items. This activity is a stress reliever and emotionally satisfying to the typical KLR owner. Much like Harley riders constantly install new parts and gadgets, KLR riders constantly buy new parts and accessories to suit their riding styles. We are enthusiasts, just on a budget and can't afford it all at one time!! It is fun getting to know your motorcycle on an intimate basis. KLRs allow the fun of Harley accessorizing, the thrill of BMW adventure touring and the youthfullness of dirtbiking all in one bike. At least thats why I have mine!!

[klrbaer]

The best mod to my ride is deffinately the tires, DURO Medians Frot and rear. I get 6000 miles from the pair. great on the road and good in the dirt.
Also looking for riding friends around central Illinois.
I moved the plate up.
Corbin seat. AWESOME!!!!
subframe upgrade
Pro gel grips
Happy trails highway pegs and Dakar guard.
Moose shifter
Moose skid plate
eliminated the inner fender
14T good in the dirt buzzes like mad at 65-80 MPH
Crampbuster on the throttle
Cruise lock
three finger clutch lever
and alot more.

[nooner818]

Originally Posted by Right Turn Clyde

nooner, I'm with ya. I like the unique bike you get with all the tinkering. But the whole "you'll save money" with a KLR gets folks thinking it's all good. Truth is, the huge list of farkle means not just plenty of customizing, but a virtual pipe from your wallet to _______ (name your vendor). That's fine, but for those of us with weak willpower and strong tinkering bents it spells: $$$$$$$$

…course, could you imagine the bill for doing the same when Touratech, etc is where you buy your bits vs. klr650.com?

I couldn't have put it better.

[klrbaer]

I'm building a single wheel trailer to pull with the KLR. I just need to haul a few things.

[HighDezert]

My KtmLR,

I got it as a basically stock '93 with 15k on the clock, which busted off when it was kicked off a cliff by some heinous dick. Broke some plastic, twisted the bars, and scratched it up a bit, but otherwise the bike was fine. Me? I hate cookie cutter bikes, or anything for that matter, and the bricklike aerodynamics of the stock fairing seemed like one of the best places to start.

Yes, that is the stock fender turned fairing. I cut out tabs where the front holes were, heated and bent the plastic till i had two tabs 90 degrees from original. I zapped two 3.5" holes and shoved some $20 driving lights in there. For the top support, i epoxied a strut that connects to my ignition switch case. It's light, and if i do happen to whack it on something the upper strut will break before anything else and it should bend put of the way. I chance breaking the light, but so what, i'll spend another $20 and glue a new set in. I've got lots of room behind the "windhshield" where i can mount some instruments, but so far i've just got my trusty GPS ziptied to my bars. The fender is a Cycra KTM fender given the Krylon Fusion treatment, as with the rest of the plastic. The front fender makes a better fairing thna stock, and i must have lost 15lbs up front getting rid of the stock monstrosity. It cuts the wind better, it doesn't get blown around as much, and i get clean airflow over the top with a minimal bubble over the tank. If i get real low i can get the air to flow over the top of my helmet at 70, but i don't ride that fast. I love having the visibility up front now, while standing i can basically look down at the area around my tire when rockcrawling. I also get a kick out of the cartoonish evil cyclops alien robot head look. When i first mounted it and stood in front, it actually looked disturbing, like it was staring at the silly humans targeted by it's death ray or summat, idk, there''s just something cold and menacing about it, but i think it's pretty damn cool.

No turn signals, i ride mainly offroad and most slab is lonely 2 lane stuff, so i got rid of 'em. On the rare occasion that i have to actually signal my intention to someone i use hand signals.

MSR hi-rise ATV bars, Tusk ATV barkbusters, Decalifornicated, Progressives with 5wt, snorklectomy, extremely high plate, i moved it up and still ripped it off somehow, so now it's wedgedf as far up as i can get it, the inner fender hangs down lower. 14T counter, man i LOVE this thing, makes it a whole different bike. Now at +9000' lofting the front is a reasonable request, with the 15t sometimes it would just mush out even with a bit of clutching, now i can get it up and over ruts, rocks, and other fun stuff.

Sportin' Kenda K270's front and rear. I like 'em, the front walks a bit if you push it on the road but it picks the best lines in sand. The rear could have a bit more bite, but it's got enough that i'll run it till it's dead. I might try the 606 next.

Sealed battery, i replaced lots of non-critical screws with zipties, it's easier to carry 100 zipties than 100 extra bolts and a gallon of loctite, that, and who would steal a bike that had hundreds of ziptie tails hanging off, looking like it was a major structural component?

Another good mod was hydraulic brake switches, get rid of the spring and plastic piece of crap on the rear and the little micro sw up front, it's an easy and cheap mod ($19 each) and no more difficult than doing a brake fluid change.

I'm a minimalist, so not much in the way of farkle, i just keep doin' what needs to be done to the beast to make it at home in mountain dirt. I plan to get the IMS tank, and i'm working on building a rack to carry this to places like this.

I'm leaving around the 12th for a little ride up to Roosville from down in Antelope Wells, so in about a month i'll know what really works and what doesn't.

[30Bones]

Good god that thing is ugly

Back to the fat shicks and mopeds joke :grinner

[Paves]

HighDezert, post some more pics

[greenfreak]

Originally Posted by R_W

Sideways, negative terminal down. Only use the metal bracket, not the plastic battery cover. You will need to make a 6" extension for that small ground cable, just bullet male and female. I shimmed the side of the box w/ some foam to keep the battery tight.

My only complaint has been tires, the scorpion AT was my least favorite-go figure. I got crap mileage out of them, I like the ST much better as a road tire.

and my un-do's have been windshield, fender, and handguards trying to find the combination that minimizes turbulence and maximizes protecton.

thanks for the input, I'll try it out today and take it for a spin in the mud to see how well it holds up... I have heard lots of complaints about the scorpion A/T's but am going strong on my second set with great on road and reasonable off road traction. Granted personal opinions differ and no tire on the market is a true D/S where traction is great both on and off road... However on a different note I would not put the pipe on if I started over again. The gain in HP is not worth the money, noise or hassle of tinkering with the jets over elevation changes. Furthermore, first gear is not as low as before. I live at 8,000 ft and ride anywhere between 4,500 and 12,000. Can you say hassle?