To Replace or Not Replace - Plastic Shrouds - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 9 Old 11-22-2018, 11:01 AM Thread Starter
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To Replace or Not Replace - Plastic Shrouds

Hello. I recently purchased a 2009 KLR650 and it had a bit of trail rash on the plastic radiator shrouds (plastic panels on either side of the fuel tank). I removed both shrouds and found that the plastic knob (feature that goes into the rubber grommets) had broken off on both the left and right side panels. The right panel also had some cracks near the air inlet opening. I did a little research and found that you can get OEM replacement panels for $122 each or aftermarket (Polisport) for about $92 each. I decided to remove the graphics to make the rash less obvious and just reinstall the panels. This improved the appearance of the bike and the panels seemed to be secure even without the knobs. Is there any reason to replace these panels if they are secure on the bike other than cosmetics? Has anyone installed the Polisport panels or other Polisport plastics on their bike? If so, how did they fit? Worth the money?

Thanks,

LB
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post #2 of 9 Old 11-22-2018, 11:32 AM
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If they are secure there's no need to replace them. The panels are ABS, so the cracks can be treated with acetone as a solvent/cement. A heat gun will help with faded plastics and may help with minor road rash (as a mild 'flame polish').

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post #3 of 9 Old 11-22-2018, 12:12 PM
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I'd replace them with the Polisports which (from all reports) are made from more durable plastic thatn the stocker's ABS - or just replace the whole shebang with an IMS tank and store the stock parts on a shelf.

Dave
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post #4 of 9 Old 11-23-2018, 07:04 AM
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My 2009 is similarly "experienced". I've chosen to live with it, as I'm not concerned with it's physical appearance. My KLR is sorta like me: getting on in years, and showing various marks of life's adventures. (I probably haven't washed it in over a year).

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post #5 of 9 Old 11-23-2018, 08:33 AM
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My 2009 is similarly "experienced". I've chosen to live with it, as I'm not concerned with it's physical appearance. My KLR is sorta like me: getting on in years, and showing various marks of life's adventures. (I probably haven't washed it in over a year).

Sent from my XT1254 using Tapatalk

And on the other hand, I like to keep my bikes as close to pristine as possible.....maybe it's a sickness!



Cheers,
Dave
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post #6 of 9 Old 11-23-2018, 10:41 AM Thread Starter
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Wow, that is pristine. Nice Gen 1 Dave. I actually prefer the looks of the older version to the Gen 2 KLR, but wanted to get something a little newer. You mentioned something about replacing the tank with an IMS tank and putting the plastic shrouds on the shelf. When I removed the plastic shrouds on my bike, I found where the radiator was partially supported by the shroud on the left side. Also, when I looked at some photos of the Gen 2 KLR with IMS tank installed, it appeared that there was still a bolt-on shroud up front. Do you know if the IMS tanks have a mounting point for the radiator on the Gen 2 version, or do you still have to have the separate plastic shrouds?

Thanks,

LB
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post #7 of 9 Old 11-23-2018, 11:04 AM
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There is but one version of the IMS 6.6 tank. ON the website it says that it works on the Gen 2. That is not exactly true.

Installing the IMS 6.6 on a Gen 2 takes a bit of doing; you might find these of interest:

https://www.souperdoo.com/stuff%20th...emi-round-hole
https://www.souperdoo.com/stuff%20th...s-to-newcastle
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Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #8 of 9 Old 11-23-2018, 11:20 AM
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Originally Posted by Indianaboyd View Post
Wow, that is pristine. Nice Gen 1 Dave. I actually prefer the looks of the older version to the Gen 2 KLR, but wanted to get something a little newer. You mentioned something about replacing the tank with an IMS tank and putting the plastic shrouds on the shelf. When I removed the plastic shrouds on my bike, I found where the radiator was partially supported by the shroud on the left side. Also, when I looked at some photos of the Gen 2 KLR with IMS tank installed, it appeared that there was still a bolt-on shroud up front. Do you know if the IMS tanks have a mounting point for the radiator on the Gen 2 version, or do you still have to have the separate plastic shrouds?

Thanks,

LB
Thanks for the kind words. There are two common IMS tanks; the 6.6 and the 10gall (there was a 5.5 but I don't think they make it anymore); The 6.6 is supposed to be a Gen1 tank but people have adapted it for use on the Gen 2 as Tom's excellent links will show you. The 6.6 is much stronger than the 10gall so unless you really need that kind of fuel capacity/range, I'd personally stick with the 6.6.

With the 6.6 very few of us use the rad support brackets as the concensus seems to be that they cause more harm than good. All I use is the two mounting bolts at the rear and the slide on pucks at the frame backbone. I also use the JNS rad guard which is an excellent pce. does this setup protect as good as crashbars? .....maybe not but I think it does a great job without the weight and hassle of crash bars on top.

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post #9 of 9 Old 11-28-2018, 06:19 PM
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I bought aftermarket ‘knobs’ which appear 3D printed. They get a screw through the panel (looks a bit rough) but secures the panel very well.
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