KLR 650 Modifications

Finished up this morning. Wrapped the coils in gorilla tape to protect the paint, then used 4 hose clamps to compress the spring. Probably not the safest but I still have all my fingers and eyesight so I'll call it good.
Initial ride impression, wth no preload...I should have done this 5 years ago. Rides nice.

I use s set of these from RMATV.



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I did a 600 in lb for mine.

So, I was wondering why I couldn't see SH** at night when riding my KLR, but after removing the fairing and having the headlight fall apart it was no longer a mystery.
Standby for the fix.......

Aouch ! :/

If you need a light in a good condition, I've one removed from a 99 KLR. (I can ship it, I'm from Montreal)

Thanks for the offer, but I've already done the deed & made an upgrade!

I managed to search & scrounge around & saw a few posts about LED headlights. Well, due to the condition of my headlight reflector, just a regular bulb was not gonna cut it! After a few wonderfully wasted hours, I found my replacement on flea-bay.

Nice LED headklight Smokediver3 !

While I'm in the area, I will share with you my modifs.
Here is my KLR 650 Gen1 "Rally"

















The job is not 100% percent terminated.
I'm still waiting for blinker and high beam dash indicator, my diy trip is still on development and I will upgrade the shock, but I had to reallocate the budget, so, no milestone planned yet.
And in the future, I want to make a paint job (certainly kawa green and purple), some decals for the tank and a new seat.

Then it was off to practice my very inadequate fabrication skills since this did not turn out to be a drop in proposition.

Nice build

But once it was fabbed up, it was a pretty easy install. Then putting the fairing back on, it fit just like it had to. I have plenty of light now. Even in the daytime I can see the light reflecting back from road signs. Night time riding has taken on a whole new "light"! (Insert rim shot & canned laughter here!)

Not a bad rig you got going on there yourself! I like the use of the fairing to hide the stuff you've added.

That's awesome. Mines starting to rust ever so slightly. Sent you a PM - would love to know the make/model of the LED light you used and where ya got it.

Thanks for sharing your upgrade!

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I got my 08 klr back in November, that had 26k miles on the clock. When I got it, all it had done was the doo and the carb. I am new to KLR's and ADV riding, but not new to motorcycles. Since I have gotten it, I have done:
progressive fork springs
EM fork brace
lowered and modified the stock fender
klr dash w/ taller windscreen
bar risers
tusk handguards
skid plate
pannier racks and panniers
rural king box that I screwed onto the factory rack
12v outlet
walmart seat cover
walmart tank bag
cramp buster
ims shifter
ebay foot pegs
PCV valve

still want:
crash bars and K60's would be nice.
I'm not entirely sure if I need a rear spring, but I'll probably get one eventually.

If anybody has any questions about the mods that I have done and wonder how well they work feel free to message me, and Ill tell you what I think.

Im looking at replacing the headlight and all that plastic on my 2008. I will be going with a Trail Tech Vapor for the dash portion of it. As far as lighting I was taking a look at the Cyclops Rally, heard good things about it and its halgenic performance. Then I ask do I need such a thing, although I do like it, probably not. I have now been looking at the JW Speaker 8700 Evo 2. This would give me enough money to purchase a center stand. However, has anybody done this. It looks like one of the best 7" out there even maybe a little better then Truck Lite and the price for one is decent. But, what bucket would be a good bucket to put it in on the KLR? I just don't know what bucket would be good, and do I stuff all the wires in the back? Im new to this.
This plasma money is burning a hole in my pocket...

Just askin': What's your impression of the effect of the PCV valve mod?

this +1

The PCV actually made quite a difference. Your not going to notice any power gains or anything like that, but it really smoothed out the motor and I have noticed alot less oil consumption.

Just happened upon this thread while looking for performance mods. Can anyone that has done the PCV mod vouch for long term use? I understand it isn't a power increase and more about reducing vibration but I have also read it can lead to oil leaks.

Looks great!

Question: Do those handguards hit the fairing prior the fork hitting the steering stops?