OK, here goes;
- regarding fork swaps, here's my post on the subject from a previous discussion:
Several things, the biggest is a new front wheel/hub and brake system. As I told you in that other thread, there is no free ride and the USD fork conversion has it's own set of issues to deal with.... Not saying there isn't an allure to it just that there are good reasons more folks don't do it. When I did the math prior to making the decision to stick with the stock forks and go with Cogent's DDC's, my total came to $2,000 - $2,500 for the USD fork conversion vs. about $350.00 and less than an hour for the Cogent stuff.
After the additional expense, fork rebuilding, respringing, revalving, dealing with the rear suspension travel issue, gauge cluster, speedo, turning radius issues......you still have a smaller hub with a smaller axle, smaller bearings and when compared to the SV caliper 320mm rotor mod, a much smaller brake caliper, pad and rotor......all of which are fine for MX use and less fine for dual sport use.
There is no doubt as to the superiority of the modern MX fork.....but unless you have it resprung and revalved properly, it isn't going to work as good as a set of DDC's and springs in the stock forks.......and even if you do those things, the rest of the KLR isn't up to making full use of them anyhow.
I'm just making you aware of all the issues; if you still want to do it after all that, knock yourself out.
As far as the brakes go: the KLR isn't heavy enough to need twin rotors IMO.....yeah, the stock brakes suck but the EM SV caliper adaptor, SV twin piston caliper and EBC 320mm rotors take it from dangerous to downright decent. add the SS line and dime mod and you're golden.