Tasman's 2009 KLR650 Tinkering Thread - Kawasaki KLR 650 Forum
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post #1 of 11 Old 08-04-2016, 02:28 AM Thread Starter
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Cool Tasman's 2009 KLR650 Tinkering Thread

A little while ago I purchased an 09 model KLR, it's in great condition even though it's covered a few miles. I bought it pretty much stock standard apart from the previous owner getting the Doo job out the way using an Eagle Mike kit. This thread will be my record of any "upgrades" I throw at it along my journey!

Mods so far:

(this list will be updated as and when I get things done or mess with anything)

- Doohickey upgrade kit from Eagle Mike
- Zero Gravity ST screen
- SW Motech crash bars and engine bash plate
- Barkbuster VPS hand guards
- Grip Puppies
- Cycle Nutz LED tail light kit


I'm getting used to riding the big thumper. Much heavier and higher than anything I've had before, but it makes for a great field of view when negotiating traffic! I was going to get it lowered (I am borderline at five nine) but my wife told me to "harden up" so yeah. It'll stay standard height...





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Last edited by tasman; 09-17-2016 at 02:18 AM. Reason: all about the updates
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post #2 of 11 Old 08-04-2016, 02:37 AM Thread Starter
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First job on the cards today was installing a Zero Gravity Sports Touring screen. The KLR is my only vehicle so it's a commuter, weekend fun bike, light gravel off-roader, shopper, etc. I do a bit of highway mileage on my commute and found myself tucking down behind the little stock screen. This one didn't come with the vinyl backing to cover the lower part so you can kind of see the back of the instrument panel through it. Maybe I'll take it off and paint the lower portion at some point.

I went for the light smoke simply because it looks way cooler.



Here's a height comparison with the stock screen held in front:



I don't like this bit where the Zero Gravity doesn't quite line up with the fairing edge like the OEM screen:



UPDATE: I've ridden with the screen a few times now and I really rate it. It pushes the rush of air up further so instead of hitting me square in the throat it's now just touching the top of my helmet. On the highway if I crouch behind the screen and look through it, it's like riding in a bubble! No wind noise at all, eerily quiet, just the sound of the big single spinning away at 4500rpm.
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Last edited by tasman; 08-09-2016 at 05:27 AM.
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post #3 of 11 Old 08-04-2016, 10:30 PM
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Fine looking bike. Really nice back rack. You could strap a medium sized pig on there. Try ridding in cowboy boots.
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post #4 of 11 Old 08-04-2016, 11:17 PM Thread Starter
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Quote:
Originally Posted by GoMotor View Post
Fine looking bike. Really nice back rack. You could strap a medium sized pig on there. Try ridding in cowboy boots.
That back rack is for a monstrously sized rear bag that came with the bike. It is HUGE! I could probably live out of it, or stash that medium sized pig inside it. Oh and that's not my riding attire, I just jumped on for the photo. I'm a stickler for all the gear...
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post #5 of 11 Old 08-05-2016, 12:49 AM
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I put about 45 pounds on the rack which is about double the speck load. Then I ride on some very rough rocky trails and heavily washboarded roads. This can crack the frame joint under the rack just behind where the upper and lower subframe tubes join.

I welded in some extra bracing under that joint to solve the problem.
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post #6 of 11 Old 08-06-2016, 06:10 AM Thread Starter
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My new SW Motech crash bars and bash plate arrived in the post!

I wasn't going to buy the bash plate at the same time as it costs almost as much as the bars, but when it arrived I'm glad I did! This thing is a beast, plus it looks awesome compared to the stock plastic one. This one makes the bike look like a proper machine!



Installation was straightforward, even for my less than mechanically gifted hands. Took me under two lazy hours in the morning (not including a trip out to buy an 8mm hex head socket) to get the bike pulled apart, crash bars on, new bash plate on then everything back together.

I didn't feel any difference or vibration on my test ride, these are the new bars with rubber inserts. I didn't even notice the bars were there.

Happy days!
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Last edited by tasman; 08-06-2016 at 06:16 AM. Reason: spelling fails
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post #7 of 11 Old 08-06-2016, 06:20 AM
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Good job. I cut my seat down some instead of lowering the bike.
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'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
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post #8 of 11 Old 08-10-2016, 08:19 AM
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SW Motec bars?

Quote:
Originally Posted by tasman View Post
My new SW Motech crash bars and bash plate arrived in the post!

I wasn't going to buy the bash plate at the same time as it costs almost as much as the bars, but when it arrived I'm glad I did! This thing is a beast, plus it looks awesome compared to the stock plastic one. This one makes the bike look like a proper machine!

Installation was straightforward, even for my less than mechanically gifted hands. Took me under two lazy hours in the morning (not including a trip out to buy an 8mm hex head socket) to get the bike pulled apart, crash bars on, new bash plate on then everything back together.

I didn't feel any difference or vibration on my test ride, these are the new bars with rubber inserts. I didn't even notice the bars were there.

Happy days!
Do the SW Motec bars still have that little gusset welded to the bars? It's just right to mount a set of highway pegs to.
Shown in this video... https://www.youtube.com/watch?v=ur7_GVyKe2Y

Ageing Gracefully



2017 Yamaha XT250
1990 Honda NX250 (Green/White)
2011 Kawasaki KLR 650 (Orange & White )

My KLR Page..http://www.powers31.info/2011_KLR650.htm

Mod's to KLR:
Power socket, L.E.D. Battery Indicator, Camera bag holder
Custom Saddlebag frames .
Louder horns, Firstgear Onyx tail bag.
Custom Aluminum Skid Plate.
Cut down seat with Custom pad.
Go Pro Camera mount.
Doo-Hicky
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post #9 of 11 Old 08-11-2016, 04:46 PM Thread Starter
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Quote:
Originally Posted by larry31 View Post
Do the SW Motec bars still have that little gusset welded to the bars? It's just right to mount a set of highway pegs to.
The gussets are still there, but there are no mounting holes for highway pegs so you'd have to drill your own.
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post #10 of 11 Old 08-11-2016, 07:01 PM
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Try the KLR dash kit with the zero gravity tall windshield. I have that setup on my 09 and it made a huge difference. It makes the windshield more vertical to cut down the wind. Check out klrdash.com for details.
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John "JohnBG' Grocke

2009 KLR 650
2006 Ural Raven (Patrol) 2WD

Love is the feeling you get when you like something as much as your motorcycle. ― Hunter S. Thompson
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