OX4 2012 KLR 650 Build - Kawasaki KLR 650 Forum
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post #1 of 9 Old 05-13-2016, 09:36 AM Thread Starter
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Join Date: Mar 2016
Location: Spring, TX
Posts: 36
OX4 2012 KLR 650 Build

Back in mid-March of this year I found a bike being sold by a gentleman who had recently retired and decided he would be moving to Greece. The bike, a 2012 model, only had 180 miles and he literally rode it twice a week to/from his house to the local post office located <1 mile away.

After taking delivery of the bike, the fun began with building it out and getting the appropriate safety gear and additional items to supplement adventure riding. Below is a photo of the bike BEFORE the build and then a photo AFTER the build. The build sheet, to date, includes the following:

- K&N Air Filter
- Sargent World Sport Adventure Touring Seat
- Yoshimura RS2 Exhaust
- Eagle Mike KLX Jet Kit w/Carb Screw Upgrade Kit
- Touratech USA Headlight Guard
- JNS Engineering Radiator Guard
- JNS Engineering Skid Plate
- Givi USA Engine Guards
- DirtRacks Heavy Duty Slide/Rear Racks
- Moose Racing Rear Brake Cylinder Guard
- Superbright LEDS LED Turn Signals, Dash and Brake Lights
- Wolfman Luggage Enduro Tank Bag, Overland Duffel, and Rocky Mountain Saddlebags
- Rigid Industries 2x2 Dually LED Lights
- Techmount GPS Handlebar and LED Light Mounts
- Whitehorse Gear Green Light Trigger
- Baja No Pinch Tire Tool
- Oxford Omega Disc Lock
- Atlas Throttle Lock
- Sena 20S Bluetooth Headset
- 12V w/USB Ports power outlet (sourced from eBay)
- Butler Maps Master Collection
- DeLorme InReach Explorer GPS w/Ram Mount
- Klim Dakar Gloves
- Klim Overland Jacket
- Klim Overland Pant
- SIDI Adventure Gore-Tex Boots
- Aerostich AD1 Over Pant

As the Publisher of OutdoorX4 Magazine (outdoor by 4), I'll be documenting the build in more detail and featuring adventure content starting in our next issue. I'll post more on the bike and adventures here and you can also read about all of it in upcoming issues of the mag. Needless to say, it's been a blast thus far with more upgrades planned including Michelin's Anakee 3 Tire, Cogent Dynamics suspension, handguards and replacement footpegs. Stay tuned.
Attached Images
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post #2 of 9 Old 05-13-2016, 10:50 AM
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Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,193
Very cool. Nice.

A couple of comments,

- The K&N is a poor choice, especially for a KLR; flow is worse than stock and filtration is dubious at best. Best choice is a UniFilter available from Eaglemike.com or elsewhere. hopefully you still have the stock filter cage or it's off to the dealer....

- you will LOVE the improvement from the Cogent suspension; night and day. I look forward to your thoughts/review

- footpegs; there are several issues with KLR footpegs. The stock ones suck and have poor grip when wet, never mind mud plus they tend not to stay put. Most wider aftermarket pegs such as the common IMS replacements exacerbate some ergonomic as well as space issues - because they are slightly taller and the extra width causes issues with the peg to shifter difference and the height causes issues with the brake pedal height. My chosen solution was the Knight Designs drop pegs which work great.KD Kawasaki KLR650 08-10 Menu Another option would be JNS's new drop peg brackets with the IMS's or another quality peg....as you probably can tell from your rad guard and skid plate, JNS makes nice stuff. 1987-2016 KLR650 Foot Peg Lowering Brackets

Cheers,
Dave
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post #3 of 9 Old 05-13-2016, 12:15 PM Thread Starter
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Join Date: Mar 2016
Location: Spring, TX
Posts: 36
Quote:
Originally Posted by DPelletier View Post
Very cool. Nice.

A couple of comments,

- The K&N is a poor choice, especially for a KLR; flow is worse than stock and filtration is dubious at best. Best choice is a UniFilter available from Eaglemike.com or elsewhere. hopefully you still have the stock filter cage or it's off to the dealer....

- you will LOVE the improvement from the Cogent suspension; night and day. I look forward to your thoughts/review

- footpegs; there are several issues with KLR footpegs. The stock ones suck and have poor grip when wet, never mind mud plus they tend not to stay put. Most wider aftermarket pegs such as the common IMS replacements exacerbate some ergonomic as well as space issues - because they are slightly taller and the extra width causes issues with the peg to shifter difference and the height causes issues with the brake pedal height. My chosen solution was the Knight Designs drop pegs which work great.KD Kawasaki KLR650 08-10 Menu Another option would be JNS's new drop peg brackets with the IMS's or another quality peg....as you probably can tell from your rad guard and skid plate, JNS makes nice stuff. 1987-2016 KLR650 Foot Peg Lowering Brackets

Cheers,
Dave
Excellent feedback, Dave. Much appreciated and I am now going to look into a new air filter as well as follow your suggestions on the foot pegs. No doubt the OEM foot pegs are no good and those are on the list for Phase 2. And yes, I've been very impressed with JNS Engineering. Quality stuff!

Regarding the suspension, do you suggest new fork springs as well? I would think the benefits would make sense but appreciate any feedback. Thanks!

Last edited by txox4; 05-13-2016 at 12:25 PM.
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post #4 of 9 Old 05-13-2016, 12:37 PM
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Join Date: Apr 2016
Location: Trinidad Colorado
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Garage
Very nice!!!!

"Things are made out of Stuff"
Bill Nye~

"Singularity is a scientific term for - We Just Don't Know"
Neil DeGrasse Tyson~

(2011 KLR)
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post #5 of 9 Old 05-13-2016, 01:39 PM
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Quote:
Originally Posted by txox4 View Post
Excellent feedback, Dave. Much appreciated and I am now going to look into a new air filter as well as follow your suggestions on the foot pegs. No doubt the OEM foot pegs are no good and those are on the list for Phase 2. And yes, I've been very impressed with JNS Engineering. Quality stuff!

Regarding the suspension, do you suggest new fork springs as well? I would think the benefits would make sense but appreciate any feedback. Thanks!
Short answer on the fork springs is yes but call Rick at Cogent and give him your weight, loading expectations and usage and he'll put together a package that will have you dialed in. Cogent's stuff is good quality and very good value for money, but the best thing is their free expertise and stellar customer service.

Both my KLR's DDC packages came with dual rate (not progressive) springs matched to my info; works great, I think you'll be very pleased.

Cheers,
Dave
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post #6 of 9 Old 05-13-2016, 01:56 PM Thread Starter
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Join Date: Mar 2016
Location: Spring, TX
Posts: 36
Quote:
Originally Posted by DPelletier View Post
Short answer on the fork springs is yes but call Rick at Cogent and give him your weight, loading expectations and usage and he'll put together a package that will have you dialed in. Cogent's stuff is good quality and very good value for money, but the best thing is their free expertise and stellar customer service.

Both my KLR's DDC packages came with dual rate (not progressive) springs matched to my info; works great, I think you'll be very pleased.

Cheers,
Dave
I've had the pleasure of speaking with both Rick and Todd at Cogent and once we get all settled, I'll certainly indicate weight, use, etc to make sure everything is dialed in as-needed.

How frequently do you find yourself adjusting the rear shock? Obviously it's dependent on additional weight and cargo. Just curious if you use that functionality regularly or no.
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post #7 of 9 Old 05-13-2016, 02:17 PM
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Join Date: Aug 2010
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Originally Posted by txox4 View Post
How frequently do you find yourself adjusting the rear shock? Obviously it's dependent on additional weight and cargo. Just curious if you use that functionality regularly or no.
I have the Moab on one KLR and for KLR#2 I went with the Adventure.....primarily because I had never adjusted the Moab after the day I bolted it in....it just worked so well I didn't want to mess with it. The Adventure in the second bike works identically and I alternate riding the two bikes back to back.

For those on a budget, the Adventure is the way to go IMO, but the free warranty/service and adjustability of the Moab is nice too.....nothing wrong with either choice.

I should say that I almost never ride 2 up and don't carry much gear; I have no panniers or top boxes and light vs. heavy for me doesn't vary more than 20 lbs or so.

Cheers,
Dave
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post #8 of 9 Old 06-20-2016, 11:07 PM
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Join Date: Jun 2016
Location: Monroe, MI
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I went Elka, but cogent on the Tenere. The next shock I get will be cogent again!


Sent from ...

'82 XV920: Soon to be tracker --'00 KLR685:adv -- '04 DRZ400E --'12 Super Tenere --'13 Versys
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post #9 of 9 Old 06-23-2016, 11:50 PM
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Looking good.

Do you rate the Rigid Industries 2x2 Dually LED Lights? How have you wired them up?
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