I'm in my rookie year with an 08 KLR that I recently got used with only 3700 miles. It was in pristine condition until I dropped it cornering on a left turn on some loose gravel (and busted up my ankle in the process). No component or fuel tank damage but the left side plastic casing is now really cracked all the way down to the bolt at the bottom.

Is there a way to repair this with JB Weld or am I better off replacing the whole facade? Anyone have an idea what a replacement of that piece costs?

I plan on doing a lot of national forest riding in the future so I'm not sure I'll be making any expensive cosmetic repairs any time soon.

You could fix and repaint the shroud but it's expensive (or takes skills) to make it look decent.

Other options;
- buy a new one from Kawi...$$$
- a 10 gall IMS tank and keep your OEM parts
- Polisport is now gearing up to start shipping aftermarket Gen2 KLR plastic.

Dave

I had a similar experience with the lower fairing on the right side, and repaired it with epoxy and fiberglass matting material.

After aligning all the pieces, I painted on the epoxy with a disposable brush and laid a layer of the fiberglass on the cracks - repeating it with another layer of material, until I used up all the epoxy.

It took all night to dry, but turned out pretty solid. Not exactly pretty, but pretty functional and it ended up totaling less than $20.00.

Best luck!

Nerfs (crash guards) have their place; especially for Generation 2s.

They sure do. However,.....they make a heavy bike that much heavier. IF I would be using this thing the way most people on this site do, I'd store the original tank, shroud, and side covers, put IMS tank on (a lot of weight saving there!), buy used side covers off of Ebay (maybe paint them to match the tank), get bigger skid plate (the one that protects the clutch/stator cover), and hit the dirt. When the time comes for selling the bike,......MINT stock pieces back on, IMS, and painted side covers on Ebay, and all is good.

Now,.....as anal as I am, I'd probably store the front fender, and other plastic pieces too, and replace it with cheap (and beat up!) pieces off your favorite auction site.

Agreed, though if you use the 10 Gall IMS or even retrofit the Gen1 6.6 IMS tank, you no longer need/can use the shrouds

Dave

That's what I meant. IMS on/shrouds off (just like YOU did!). Selling the bike, IMS on Ebay, preserved plastic back on.

KLR650s remain hardly Pebble Beach Concours d'Elegance candidates, but . . . what's the delta between IMS cost and premium for new plastic when selling a used KLR650?

Of course, a used IMS has some value. IMS cost vs. cost of nerfs may be a wash.

It depends what crash bars you are looking at but generally the cost of an IMS tank vs. crashbars is very close; my Gen1 6.6 IMS was $274.00 and the PD bars were $289.95. I wouldn't do it just to get more money at resale time but I'm sure it would help.....how much depends on a plethora of other details. I do it 'cause of the benefits particularly around weight and resiliency.

Dave

Also, as Danielsand has recently found some colors of some years KLR650 New Body parts are already No Longer Available. And pristine used are in very rare supply, if not also NLA.

I wished that I had had the $ to purchase complete Lime Green/Black 2006 body parts and fuel tank in 06 or 07. To retro fit onto my chalky White 1987.