Headlight Protection - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 20 Old 04-15-2008, 07:45 PM Thread Starter
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Headlight Protection

Hey guys, thought I would share a quick mod we did on our headlights. I have always wanted some kind of protection up front for rocks being kicked up by accident from someone being in front of me to protect the headlight lens. I picked up a set of wire headlight guards on EBay for less than 10 bux shipped. It is pretty easy and quick to do. First remove your front signals, fairing, and the cover over the headlight. Also you will need to remove your front fender to make it easier to drill the metal housing from the bottom.
We used six lengths of velcro (hook side) with adhesive on the back. Make them about 1/2 in width and about 4 or 5 inches long. You will place two pieces on the top section, two on the bottom and one on each upper side. You will need to drill two holes in the top of the metal bracket, one on each outter side and do the same on the bottom. You will use the existing hole towards the top on the sides. Slide your velcro thru the guards as you will see in the pictures below and press the adhesive sides together. We used an electrical tester to make holes thru the velcro in relation to the holes in the metal bracket. Then slide a zip tie thru the velcro down into the bracket and pull it tight. Small or medium sized zip ties will work fine. Just make sure that bracket is centered up good before cinching the ties down real hard. Clip off the zip tie ends and you are finished. Reassemble fairing. I like all those nice headlight guards that are out there, but I do like the $8 guard I have better. The remaining $50 I would have spent can now go into the fuel tank. Hope you find this to be a helpful and useful mod. Ignore the date stamp on the pictures, the batteries fell out and I didn't reset it.

4X4 Headlight guards from EBAY:


Velcro Stips cut to length


Velcro applied to the guard:


Drill four holes, use two existing side holes:


Use something to make holes in velcro for zip tie to go thru:


Install zip ties


Finished product


fairing replaced


Buddies red 05

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #2 of 20 Old 04-15-2008, 08:32 PM
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Hello Dx. I was thinking of the same thing but didn't see the guard on ebay. I bought the cee baileys clear lexan guard ( essentially a rectangular) piece of plastic. Hey Dx, have you seen the Patman airbox mod with the mercedes benz one way valve at KLRWORLD.com. Just did it and it only costs me 10 bucks in parts and 10 minutes of time

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat
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post #3 of 20 Old 04-15-2008, 08:59 PM Thread Starter
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Yes I have read that many times, but I am having problems finding the MB valve. Did you use the MB valve or something else and where did you find it? I think I will definately do that mod soon as I get everything together.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #4 of 20 Old 04-15-2008, 09:08 PM
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I went to the local MB dealership. Had one in stock for 11 bucks. they are ordering more. I was thinking about getting 5 or 6 and selling them with the hose. Do you have a MB dealership near you?

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat
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post #5 of 20 Old 04-15-2008, 09:12 PM Thread Starter
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No I don't, that is the reason for my problems...LOL..the local parts stores look at me like I am crazy when i ask for one..

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #6 of 20 Old 04-16-2008, 12:17 AM
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I'll call tomorrow and see if I can order 5 or 6

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat
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post #7 of 20 Old 04-16-2008, 12:34 AM
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[FONT='Arial','sans-serif']http://klrworld.com/forums/index.php?topic=4193.0;highlight=pcv[/font][FONT='Arial','sans-serif'][/font]

quote: "The yellow hose is called 3/8" ID spray hose, PN 048643-065246.
And the valve thingie part number is 271-018-00-29. its a Supercharger Check Valve for the 4cyl C230 engine."

quote: "Instead of drilling an extra hole in the side for the sole purpose of vacuuming out the chips, you could heat the drill bit (old one) with a torch and just push it through with slight turning action. You won't end up with chips in your air box, and the smell of that particular type of plastic melting will leave you with quite the "Smell Memory" embedded."

I am going to re-do my PerCiVal to the newer PCV 2 mod.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015

Last edited by tomatocity; 04-16-2008 at 12:37 AM.
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post #8 of 20 Old 04-16-2008, 06:30 AM Thread Starter
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Thanks for the update tomatocity, I had forgot about heating the bit...

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #9 of 20 Old 04-16-2008, 10:24 AM
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DX, I ordered 6 more. Should be here tomorrow-they said. I'll reserve one or two for you and your riding partner. I'll pm you when I get them

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat
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post #10 of 20 Old 04-16-2008, 06:51 PM Thread Starter
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Great, I would appreciate that!!

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

Best Auto/Moto Insurance | Motorcycle Protection Today | FREE Trade-In Quote
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