My Vision of an Adventure Bike-06 KLR - 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 19 Old 06-09-2015, 01:43 PM Thread Starter
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Join Date: Jun 2015
Location: Bathurst NB
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My Vision of an Adventure Bike-06 KLR

Ok Ladies & Gents, Here we go.....

Long story short, spent most of my teen years tearing it up on 2 stroke YZ's, spent the bulk of my adult years so far fixing/building/tearing it up on early 70's Honda CB SOHC's. Never owned a Kawasaki before but my friend Jay had an 05 or 06 KLR and he would go from New Brunswick to Newfoundland and try to break the previous record by lowering his distance on pavement every year. I always found something esthetically pleasing about his paritcular model but I moved, he moved and I sort of forgot about that wonderful looking bike. Fast forward 6 years and my son wants to get into more extensive trail riding so I sold my 73 CB750 in search of something suitable for riding with him but would still work as a commuter to work.

Turns out the guy around the corner is selling his 06 KLR. Went for a test ride and was blown away by the bike. Never felt power like that before in an off road bike!! I was sold. Did a pile of research, asked lots of opinions of every KLR owner I know and in the end I brought it home. Since then I have put around a hundred km's on the bike, mostly trail riding with my son, already learned how to get the rear wheel off to change a tube and am starting to enjoy the simplicity of a single cylinder.

One of the jokes to my son was I want a bike that will carry me through the Zombie Apocalypse....I'm confident I have found it!!

That said, there have been a number of mods to the bike already and will list them to the best of my knowledge. Pretty sure these are all aftermarket, if they are stock please feel free to educate me...I wouldn't know stock if it slapped me in the face.

Rad and engine guards(unknown maufacturer)
Moose handlebar guards
Serrated wide footpegs
Cramp buster throttle paddle
12V and USB plugs on the dash
Toggle switch on the top/back of the headlight assembly(don't know what it does)
Performance brake discs (have the originals)
Progressive rear shock (have the original)
Centre Stand
Set of barely used street tyres
Extra front fender end piece

If anyone has any input on things that should be done (like the doo-hickey) plse feel free to post. I wish to be educated!!

Pictures and more to come as this beast evolves.....
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post #2 of 19 Old 06-10-2015, 01:36 PM Thread Starter
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Join Date: Jun 2015
Location: Bathurst NB
Posts: 55
klr1.jpg

klr.jpg

Here is how it sat when I picked it up
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post #3 of 19 Old 06-10-2015, 02:09 PM
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Join Date: Aug 2008
Location: midwest
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you have the rear shock done....go ahead and put the progressive monoshocks in the forks
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post #4 of 19 Old 06-10-2015, 11:06 PM
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Join Date: Jul 2014
Location: Alberta
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Originally Posted by johnnail View Post
you have the rear shock done....go ahead and put the progressive monoshocks in the forks
I am not sure the monotubes are available for the gen 1. I would recommend Cogent Dynamics drop in dampening cartridges and springs.
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post #5 of 19 Old 06-11-2015, 08:43 AM Thread Starter
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Join Date: Jun 2015
Location: Bathurst NB
Posts: 55
Appreciate the input....for the moment I am just going to ride it as is until I get used to it, then figure out what mods I would like to do and from there carry out those I can afford to do.....

Short term will be to ride it, paint the faded plastic, clean it up and become familiar with my new bike.
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post #6 of 19 Old 06-12-2015, 05:42 PM
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Join Date: Jan 2014
Location: Phoenix, AZ
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Looks like a great bike, congratulations.
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post #7 of 19 Old 06-13-2015, 11:23 AM
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Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
There are a few modifications possible to the KLR. Here's the list on my present bike which are not all duplicates of those on my previous one or which have done on others. Depending on one's use, my mods may be useful or not as they are improvements mostly for my uses.

POwner mods 30+
The racks are the SU model from Happy-Trail.com.

The ammo cans are mounted by way of the L-shaped mounting brackets from KLR650.com and hex bolts. Allen key included.

Moose Racing Nerf Bars

Tank pad

Studebaker MM230 Skid Plate (engine guard)

Lever guards Mair Woods

Muffler modified HMF end cap

Mesh Headlight Guard

Rear Master Cylinder protector

Stainless brake hoses F & R

EBC FA67/3 brake pads
EBC FA130R Disk Brake Pads

Ricor Imtiminator fork valves

Race Tech front fork springs 492 mm free length 4.45 mm wire diameter, 140 mm spacer

Dial-A-Jet main jet adjustment kit.

EZ-Idle mixture adjustment knob

#38 pilot jet

#150 Main

Africa Left side switch pod.

Mirror relocation mount.

Eagle Mike frame bolt kit

Eagle Mike Doohickey with coil spring

IMS Foot Pegs

Foot peg mount bolt upgrade

Low windscreen deflector

Remove inner fender, license light mount, and relocate licence to rear fender

Elastic stop nuts on chain adjuster studs

Krylon Repaint

Re-profiled seat.

Bowl vent "T"mod.

1" KLR bar risers



My modifications to KLR#2
1) Convex mirrors onto originals
2) Pro Grip 714 Dual Sport grips
3) EBC-CSK Clutch springs
4) Shift lever sapling stopper cable
5) Charge adapter for battery to starter relay
6) HID headlight kit
7) Lexan headlight protector
8) Main & Headlight fuses to weatherproof micro fuses
9) Steering head grease nipple
10) Steel reinforcement plate RTV behind shift lever
11) #2357 tail light bulb
12) Seat modified to remove w/o bolts
13) Advance exhaust cam (1) tooth
14) Replace coolant hoses w/3/4” heater hose, (2) x 6” coil springs, & Goodyear #65009 hose
15) Yamaha cross bar pad
16) Extend rear signal wires to allow connection under seat
17) Brake pedal riser carriage bolt
18) 306-5029 Motion Pro (Yamaha ATV) clutch cable
19) Recalibrate speedometer
20) Dual Sport Luggage Trunk top case
21) Dash 1/16" Lexan
22) Voltmeter
23) FIAMM E72102 horn
24) Remove air box screen
25) Drill carb slide vacuum port to 7/64”
26) Main power relay
27) Rear shock gravel shield
28) 4-Way hazard switch
29) E13 Tridon flasher
30) Heated jacket plug
31) Cigarette plug
32) Grip heater wiring
33) Cooling fan fuse relocated lower down to weatherproof Mini Fuse
34) EBay rotary LED controller board & potentiometer installed to control grip heaters. (2.9 amps max to grip heaters at 14.5 volts)
35) Temperature gauge calibrated overlay
36) KLX needle clip in 3rd slot
37) Thermostat bypass
38) Spread rad. side plastic shroud & zip tie to HT guard. Insert water pipe foam between rad. & shroud. Aim is to increase air scoop effect of rad.
39) Convert front turn signals to 40 LED panels. Always on running flash off/on for signals.
40) No Toil air filter
41) Weld larger foot to side stand.
42) LED lights to bark busters.(rewired to operate in unison with front signal lights)
43) Install 195 F thermostat.
44) Cross drill oil pipe banjo bolts to 1/8"
45) Metal heat shield onto water pump hoses
46) NK Lexan windscreen
47) Install (2) flat 4-wire trailer connectors to rear light wiring.
48) Drill (8) ” holes in top of air box
49) Install (2) 4-wire trailer plugs to R & L side rear wiring & glue lights to rear of ammo boxes.
50) Tubeless tire conversion: 224 Acrylic body sealer, sealed spokes to rim. Cleaned inner wheel with PF600 & installed Ken’s Tire tubless stems.
51) 14 1/8” x 1/8” Lexan Windscreen 25 + 47 = 72 mods
52) Replace dash #194 bulbs (speedo (2), tach, Fan, + (2) pannier tail lights with LED
53) Spray side boxes w/rubberized underbody coating
54) Add reflective strips to side boxes.
55) Drill oil gallery (below starter) & cylinder head banjo bolts to (2) 1/8” holes from single 1/16” hole/
56) Brown Wire Modification
57) Exhaust elbow onto muffler.
58) Plasti-Dip Tupperware to Blaze Geen
59) 10mm Ninja 250 master cylinder
60) Silicone 1-1/4" x 10-1/2" aluminum plate to LH side of rad.
61) Automotive rubber door edge around rad fan shroud between shroud and radiator core as cushion and seal air.
62) Plasti-Dip hand guards to Blaze Green
63) Solder white shunt wire from output of Main Power Relay to White wire terminal of fan relay plug to reduce fan Vd by 0.3 volts.
64) Replace cooling fan blades with EX500 fan blades. Much more air flow and higher current draw showing increased motor load.
65) VRR MOSFET EBay Suzuki Marauder VZ800 2005-2006
66) Tubeliss Tire System installed front tire
67) Slime both wheels
68) Magnetic drain plug
69) Exhaust wrap onto header pipe
70) LED Brake Tail light assembly
71) Velcro to underside of seat to prevent sliding
72) Modify fuel filler cap to allow push to close without key
73) Gen2 280 mm front rotor with counter bored bolt holes
74) Suzuki SV650, Vstrom, Versys dual piston front caliper with Deville adapter
75) Fibreglass screen between radiator and radiator guard screen
76) Gen2 header pipe with exhaust wrap
77) Modify rear swing arm brake hose bracket to hold hose on top of swing arm
78) Hydraulic clutch
79) Rear "faux muffler" 4 inch PVC tool tube
80) IMS Type rear foot pegs with springs
81) 4 inch PVC front tool tube
Total 30 + 81 = 111 mods
Planned: 3mm oil gallery restriction between oil filter cavity and crankshaft oil pocket; grease nipples in rear suspension & swing arm; self cancelling turn signals; security immobilizer from LED Pulse with remote modulator; Wheat Whacker mod to fairing.
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post #8 of 19 Old 06-13-2015, 08:18 PM
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Join Date: Aug 2009
Location: New Hampshire
Posts: 1,063
Quote:
Originally Posted by Operator View Post
Ok Ladies & Gents, Here we go.....



If anyone has any input on things that should be done (like the doo-hickey) plse feel free to post. I wish to be educated!!

Pictures and more to come as this beast evolves.....
FWIW: Regarding the Doo-Hicky. I just did my 2011 KLR.
The innards were like new, but the spring had NO tension.
It doesn't seem to feel any different to me. Still runs good. I guess the difference is, now when I do the adjustment, it's actually doing something.

Ageing Gracefully



2017 Yamaha XT250
1990 Honda NX250 (Green/White)
2011 Kawasaki KLR 650 (Orange & White )

My KLR Page..http://www.powers31.info/2011_KLR650.htm

Mod's to KLR:
Power socket, L.E.D. Battery Indicator, Camera bag holder
Custom Saddlebag frames .
Louder horns, Firstgear Onyx tail bag.
Custom Aluminum Skid Plate.
Cut down seat with Custom pad.
Go Pro Camera mount.
Doo-Hicky
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post #9 of 19 Old 06-15-2015, 07:20 AM
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Join Date: Feb 2013
Location: Maine
Posts: 368
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Quote:
Originally Posted by Operator View Post
I wouldn't know stock if it slapped me in the face.

Rad and engine guards(unknown maufacturer)

Toggle switch on the top/back of the headlight assembly(don't know what it does)
The rear inner fender has been removed and the licence plate moved to the outer fender with a generously sized licence plate light.

That radiator guard looks like Happy Trails.

I'd wager that a switch there would turn on/off either the headlight or the outlets. Easy enough to test. Shouldn't be hard to trace the wires either; it could be for a modification that's no longer there.

Enjoy!
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post #10 of 19 Old 06-15-2015, 09:37 AM Thread Starter
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Join Date: Jun 2015
Location: Bathurst NB
Posts: 55
I have tried the switch, so far no effect on the radiator fan or the headlight. This week I will be checking to see if it affects the 12v/USB plugs.

There are a couple other things I discovered:

Rear master cylinder guard
Stainless Steel brake lines

I will definitely post more as I find it and as my plans progress.

It's like a motorized scavenger hunt at this point!!
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