Building a 2008 Kawasaki KLR650 for Overland Travel!

RedRocker

Adventurer
Curtis in Texas said:
Too bad you’re in Utah.

There’s a bunch of us going to Arkansas next week for some R&R.

We’ll be doing a little street, a little dirt, and some serious single track thrown in for grins.

There could be about 100 Dual Sport Bikes all together, with group rides of about 6 to 10 riders. It’s a Very un-official this year. It's called "The Un-Official Fall Colors Tour",
The 1st rally point is Clarksville Arkansas.

Most riders will be on some serious Expedition Prepped KLR's.

Last year we had to share the Pig Trail Rd. with the Harleys and Barca Hondas some. But we would turn off on the nearest dirt roads and leave them to the Asphalt. We tried to stay off the pavement as much as possible unless it means the only way to get to the next dirt road.


I'll be leaving early and looping up into Missouri first.

Gonna do some Camping :camping: and some Hotels when I feel like a soft bed.

Curtis

Where are you living Curtis?
 

Dave Bennett

Adventurist
6 Months in Storage

Well, after over 6 months in storage while I was deployed I figured it was time to go out and clean her up a bit.

I stored it with the fuel tank 99% empty so I added some fuel and tried to turn it over... sounded almost like the starter was stuck (buzz!) but had enough power for headlight etc. so I pulled the seat to get at the battery and put it on a 2A trickle charge over night.

Went out in the garage today, charger was showing 100% (13.2 v) so I disconnected everything, set the choke and voila!

She fired right up! :victory:

I cant wait to get her out of the garage!!!:bike_rider:
 

Ozrockrat

Expedition Leader
Probably too late but some feedback for you on panniers

You have probably got all this sorted by now but I will throw it out for anyone else checking this thread out.

I had a 08 KLR in Chile / Argentina for a few months. It had Caribou panniers on it when I bought it. The Pelican boxes were great but the brackets were not up to the task. I had so many failures (although Caribou did replace some of the brackets etc free) that I ended up having the frame welded up completely and additional bracing put in. It was still putting lipstick on a pig though as the still got fatigue cracking.

I have also used a KLR on the same roads with Jesse panniers and they came through without a problem. If I was to do it again I would sell the Caribou's and fork out the cash for Jesses.

Anyway thats my .02c worth. I am sure there are plenty of happy Caribou customers and their customer support in the form of replacing the brackets for free was good. I could of just done without the hassle of getting repairs done (with my crappy spanglish it was a challenge)
 

Ozrockrat

Expedition Leader
Automatic Chain lube

Ah forgot my other suggestion is to get an auto oiler for your chain. And then don't worry about a center stand as it takes away some of the ground clearance.
 

805gregg

Adventurer
Ah forgot my other suggestion is to get an auto oiler for your chain. And then don't worry about a center stand as it takes away some of the ground clearance.

You already lot 2" by getting an 08 the older model, have 2" more ground clearance and are 100 lbs lighter.
 

T.Low

Expedition Leader
The Wee is a great bike - excellent on the super slab, just not nearly as good in the dirt as the KLR.

.02


Your 2 cents is worth about .55 US. You're right, its all about priorities. My Dual Sport is made for about 95% dirt+5% street. Someday I want to get a big bike too so i can do the Big Trailie Ride.

I would be interested to hear how the two models (new KLR vs old KLR) compare off road.

That new one of yours sure looks good.
 

Ozrockrat

Expedition Leader
Where are you getting this weight info from? Please cite a source - I've ridden both and dont think this is accurate.

Yep I think he is a bit off the mark as well. He is right on the unladen travel being 2" higher but if you look at the sag specifications they are about the same.

I have owned a few KLR's from one of the 1st 650A's that I rode up Cape York in Australia (no electric start on that beast) through until the 08. The 08 onwards are definately the ones to have.
 

William

Observer
Yep I think he is a bit off the mark as well. He is right on the unladen travel being 2" higher but if you look at the sag specifications they are about the same.

I have owned a few KLR's from one of the 1st 650A's that I rode up Cape York in Australia (no electric start on that beast) through until the 08. The 08 onwards are definately the ones to have.

Yep, too true. Sag is about the same, as Kawasaki firmed up the suspension and increased the fork tube diameter to compensate for the decreased ride height, while giving the bike better handling. That's a good thing, right?

Kawaski's website states a curb weight of 432 pounds for the new KLR, and 410 pounds for the prior KLR version.

Speaking of sag, TACODOC, what are your plans for suspension mods? Sounds like you're a clydesdale, like me, and the stock springs and shocks on the KLR couldn't handle my 230#.
 
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Dave Bennett

Adventurist
I'm taking the frugal, simple route with this project, so I will flog the OEM setup until it is hashed and then install a more robust setup. I will most likely consult the KLR god Eagle Mike in SD before I take the plunge ;)
 

Dave Bennett

Adventurist
A long ride today...

Took the 15 south to the 76... up and over S16 to the 79... out to the 371 through Cahuilla country... to the 74 and up to Santa Rosa truck trail aka the trail up to Toro Peak... back down the 74 through Hemet to the 215 and home... about 150 miles round trip :bike_rider:

100_2897-1.jpg


100_2904.jpg


The newest mod, a Pelican 1520 tailbox. This makes carrying stuff so much easier ;)
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