SW Motec bar installation insanity - 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 31 Old 01-22-2009, 01:54 PM Thread Starter
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Join Date: Dec 2008
Location: Santa Barbara, California
Posts: 30
SW Motec bar installation insanity

Dear Group.
I bought the Motec bars and center stand and spent 6 hours, 3 beers, and two scraped knuckles putting them in last night. Nice to get to know how to dismantle the bike a bit, but one thing that wasn't really covered in the cryptic directions. On the right side, you have the center stand spring braces, and so this little piece is extra on the right side. But the Motec directions don't show how this little piece, and the bars and the footpeg, go together, and also the bolt package doesn't have enough longer bolts to get through all of them. Am I going nuts? I'm no mechanic, but can do the basics, but this thing is confusing.
Secondly, my original spark plug was a NGK DPR8EA with a 9 below that. But the new one they gave me at Kawi is a DP8EA-9 (missing the R). The bike seems to run fine, but any idea why the discrepency, and if this spark plug is right?
Thanks. Having a riot on the bike. Anybody passing through Santa Barbara I'll be glad to show you a few road and off road super rides.
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post #2 of 31 Old 01-22-2009, 03:43 PM
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Welcome Greg,

I hope you don't mind I moved your thread to this forum. I think this is better home for it.

And yes some great riding in your neck of the woods. Refugio Road, 154, Santa Ynez, etc...

Take care,


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post #3 of 31 Old 01-22-2009, 04:22 PM
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Those are the same bars I got, Mark. Get excited.

"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

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Soon, we ride.

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post #4 of 31 Old 01-22-2009, 07:21 PM
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I have never installed any of the things you are so i can't speak specifically of that. However, when the directions appear to have been translated from chinese to korean to potugese or whatever and then back into engrish throw them away. (Be Doing!). Just study the problem and correct it. If parts are missing or wrong call the manufacturer (good luck), send it back or fix it yourself.

The very best installation instructions I have EVER seen are from the Watt Man who sells the Thermo-Bob. A little long and very detailed with photos. Amazing.

A spark plugs "R" designation means it has a resistor built in to reduce static emissions that can be harmful to other electronic components....engine management systems, on board computers, radios and so on.

Not so sure if that would be a concern on the KLR. All I can think of is ignition module interference.

Anybody else?

Gray-haired riders donít get that way from pure luck.


Last edited by flash; 01-22-2009 at 08:12 PM. Reason: Addition
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post #5 of 31 Old 01-22-2009, 08:06 PM
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Location: Ketchikan Alaska
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I have alway's been under the impression the (R) resistor sparkplug was for radio interferance like a99flash had mentioned. It is noticed if I run them in my boat on the VHF radio alot of static. We run the non resistor plug's in our snowmobiles some of them are EFI and no problems. I wouldn't worry any.
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post #6 of 31 Old 01-22-2009, 09:13 PM
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The current plug in my and Double A's bikes are non resister. No issues.. I was concerned about it and my GPS, but it didn't affect it at all, and I ran that plug all summer long, as did he.. Just fine..
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post #7 of 31 Old 01-23-2009, 11:02 AM Thread Starter
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Join Date: Dec 2008
Location: Santa Barbara, California
Posts: 30
Crash bars and spark plug

Thanks, guys. It's true that the SW Motec was missing two longer bolts, which I bought. With the center stand, center stand spring piece, Motec bar, and foot pegs, these bolts go through a lot a metal on the right side. Looks fine, though. If I had to do it all again, it would only take maybe 2 hours. Those directions truly suck. Maybe they're trying to funnel business to the dealerships for install by having tough instructions.
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post #8 of 31 Old 01-23-2009, 11:51 AM
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Did you by chance take any pic's of your install ? That would be some good info for other's attempting this install later on.
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post #9 of 31 Old 01-23-2009, 01:14 PM Thread Starter
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Join Date: Dec 2008
Location: Santa Barbara, California
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Motec instal photos.

I did not take photos. One reason is that when I try to download my bike photos to this site, it always says my photos are too large. This is after I've shrunk the size of them a lot. Then I see lots of photos of guy's KLRs and wonder what I'm doing wrong. I'm not a computer idiot, either, and often download photos to adventure sites. If I could download, I could take a handful of close-up photos of the Motec bar contact points which could pretty well describe the Motec install process. For instance, I don't think you have to actually remove the tank, but just lift the butt of it for access to the frame bolts. Knowing this would have tremendously reduced the hassle of the install.
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post #10 of 31 Old 01-23-2009, 06:03 PM
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Create an account at photobucket.com then upload your pictures to there. Once uploaded, have the forum open and your album on photobucket opened. You then find the pic you want to post and click on the IMG option under the picture, this copies it, then here in your post you just right click and paste. Do a preview of your post and make sure the pic posted correctly. I also found out you can adjust the size of your pictures uploaded to photobucket, I use the 1024x768 option on photobucket, this makes a really nice big picture to see. Make sure to have the size option set before you upload. Hope this helps...

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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