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Just got my first KLR (2003) Wahoo!!!

Front brake is unimpressive and I am looking to upgrade on a budget. Switching to a dual piston caliper with a larger brake pad seems like a good move and possibly the most budget minded option. Looking for a cheap option as I just blew my wad buying the bike...

I have seen a lot of folks running the sv650 caliper but almost everyone is running the 320mm rotor which ups the cost of the upgrade quite a bit.

Anyone running the caliper with stock gen I rotor?

Any suggestions for upgrading the brakes without spending a ton?

thanks

-Will
 

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I went with the Tusk 320 mm Rotor Kit (P/N: 1372220008) and their braided Front Brake Line (P/N: 1201540016) as well. I did some shopping and spent $149.99 and $44.99 respectively. I kept the stock Brake Caliper. The results have been great. OTOH if I had to do it over again I'd have used Eagle Mikes 320mm Rotor and his SV650 Caliper conversion. IMHO I don't think putting an SV650 Brake Caliper on the stock rotor, even if this is possible, would do much for improving the brakes. Going from 250 mm to 320 mm on my 2007 is what makes the biggest improvement.
 

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i have a 1st gen also, and just purchased the SV650 caliper. i am going to TRY to see if i can make this same combo work. i will let you know how it works out
 

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There is a 100+ page thread on .com if you want to know everything there is to know about the whole "$21 brake mod " (as it was originally called)

bottom line is that the SV caliper won't work/fit with the stock Gen1 rotor. The SV caliper upgrade makes at least as much difference as the 320mm rotor does; together they give you a Gen1 with a decent front brake - unlike the stocker.

I'd suggest saving your pennies and getting the SV caliper adaptor and an EBC rotor from Eaglemike. There is more than one EBC 320mm rotor for the KLR and EM stocks the right one - the other one has clearance issues. You can take a chance with alternate rotors but no guarantees that you won't run into interference issues.

If you're really on a budget, you can build the caliper adaptor yourself; there is a .pdf file out there, I have it on my other computer if you want to try it; I made my first one before Mike started making then. You can get the SV caliper on ebay and there are a number of other bikes that use the same unit - let me know if you want a list and I'll try to dig it up I've seen them for as cheap as $20 .......but you'll still need a rotor.

Dave
 

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...oh and I believe NormK made an adaptor for the Gen2 rotor (280mm compared to the Gen1's 254mm IIRC) and the SV caliper but I'm not sure if he was able to get full pad engagement.

Dave
 

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klrforum dot com/1987-2007-wrenching-mods/10309-mod-gone-wrong-2.html

im thinking something like this may work.

im not sure what the .com site is or where to look for the 100+ page thread
 

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Here's a Template with Suzuki Part Numbers and Applications to mount a Suzuki (Tokico) Dual Piston Caliper to a Gen1 KLR650 with a 320mm Aftermarket Rotor.
EM's SV650 Caliper Bracket is on Back-order (per his website) and I'm not sure if or when that will change.
The image was created as 8" X 10". If you print it as this, on 8.5 X 11" paper, the 1" Square Box should measure 1" X 1" and the template dimensions will be correct.
 
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