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Discussion Starter #1
Hey guys, thought I would share a quick mod we did on our headlights. I have always wanted some kind of protection up front for rocks being kicked up by accident from someone being in front of me to protect the headlight lens. I picked up a set of wire headlight guards on EBay for less than 10 bux shipped. It is pretty easy and quick to do. First remove your front signals, fairing, and the cover over the headlight. Also you will need to remove your front fender to make it easier to drill the metal housing from the bottom.
We used six lengths of velcro (hook side) with adhesive on the back. Make them about 1/2 in width and about 4 or 5 inches long. You will place two pieces on the top section, two on the bottom and one on each upper side. You will need to drill two holes in the top of the metal bracket, one on each outter side and do the same on the bottom. You will use the existing hole towards the top on the sides. Slide your velcro thru the guards as you will see in the pictures below and press the adhesive sides together. We used an electrical tester to make holes thru the velcro in relation to the holes in the metal bracket. Then slide a zip tie thru the velcro down into the bracket and pull it tight. Small or medium sized zip ties will work fine. Just make sure that bracket is centered up good before cinching the ties down real hard. Clip off the zip tie ends and you are finished. Reassemble fairing. I like all those nice headlight guards that are out there, but I do like the $8 guard I have better. The remaining $50 I would have spent can now go into the fuel tank. Hope you find this to be a helpful and useful mod. Ignore the date stamp on the pictures, the batteries fell out and I didn't reset it.

4X4 Headlight guards from EBAY:


Velcro Stips cut to length


Velcro applied to the guard:


Drill four holes, use two existing side holes:


Use something to make holes in velcro for zip tie to go thru:


Install zip ties


Finished product


fairing replaced


Buddies red 05
 

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Hello Dx. I was thinking of the same thing but didn't see the guard on ebay. I bought the cee baileys clear lexan guard ( essentially a rectangular) piece of plastic. Hey Dx, have you seen the Patman airbox mod with the mercedes benz one way valve at KLRWORLD.com. Just did it and it only costs me 10 bucks in parts and 10 minutes of time
 

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Yes I have read that many times, but I am having problems finding the MB valve. Did you use the MB valve or something else and where did you find it? I think I will definately do that mod soon as I get everything together.
 

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I went to the local MB dealership. Had one in stock for 11 bucks. they are ordering more. I was thinking about getting 5 or 6 and selling them with the hose. Do you have a MB dealership near you?
 

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I'll call tomorrow and see if I can order 5 or 6
 

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http://klrworld.com/forums/index.php?topic=4193.0;highlight=pcv

quote: "The yellow hose is called 3/8" ID spray hose, PN 048643-065246.
And the valve thingie part number is 271-018-00-29. its a Supercharger Check Valve for the 4cyl C230 engine."

quote: "Instead of drilling an extra hole in the side for the sole purpose of vacuuming out the chips, you could heat the drill bit (old one) with a torch and just push it through with slight turning action. You won't end up with chips in your air box, and the smell of that particular type of plastic melting will leave you with quite the "Smell Memory" embedded."

I am going to re-do my PerCiVal to the newer PCV 2 mod.
 

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DX, I ordered 6 more. Should be here tomorrow-they said. I'll reserve one or two for you and your riding partner. I'll pm you when I get them
 

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Paulo are you riding to EagleMike and Buddy's Tech Day in Julian, 4/26/2008? Betcha you could get rid of all the ones you have, get some stuff done on your KLR, and enjoy two wonderful rides.
 

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Tomato, I wish I could say I could as I used to reside in So Cal (80 miles from San Diego. Wife's job moved us to Cincinatti for 2+ years but with my constant complaining of loss of lane splitting and year round riding weather we will be moving to Freemont, CA in 3 weeks. Whoever want's them can PP me. I know they'll sell like hotcakes on klrworld.
 

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I just done this mod on my 06 KLR and think it worked out great.

When you buy these on eBay you end up with a pair....so I have one left. I also overbought the velcro as well.

I have enough to do another bike.

As my first post here I would like to give it to someone that wants to do this - first reply get dibs.

Shipping is on me - utterly free......

thanks
 

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Back to the light mod.

I did the same thing a couple of years ago but used zip ties instead of velcro. I've been thinking of revisiting that because it's not easy to clean the headlight with the guard attached.
 

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