Project KLR

a.k.a. modding the bejeeses out of it...

As I'm modding the KLR, I'm trying to take pictures of the step by step process.  These pictures are in the order of how the work is done.  I will have to do some backtracking since not all of the parts were available at the beginning of the process.

Step 1 - Get her naked:

• From the Left
• From the Front
• From the Rear

Step 2 - A little maintenance:

• Cam Guides
• Valve Head
• Intake shim number 2 removed
• Not pictured - Subframe Bolt Upgrade kit installed
• New carb pilot fuel/air screw...don't need screwdriver to adjust

Step 3 - Happy Trails Radiator Guard/Highway Pegs Added:

• Radiator Guard installed - front view
• Radiator Guard installed - left view
• Radiator Guard installed - right view
• Front view of both the radiator guard and footpegs
• Radiator Guard and Pegs from the left side
• Radiator Guard and Pegs from the right side

Step 4 - Handlebar Work

• Left side Acerbis Handguard
• Right side Acerbis Handguard, and SS brake line
• Throttle grip with Kimpex heaters and Vista Cruise
• Switch location (temporary) for the Kimpex heaters
• Not Pictured - tall windscreen installed

Step 5 - Misc Additions:

• Happy Trails Fork Brace Added
• Not Pictured - Progressive Fork Springs installed
• Dual-Star Bash Plate added

Step 6 - Luggage:

• Happy Trails SU Rack installed
• The Givi 36L saddlebags from the rear
• Dual-Star TankBag and Panniers - side view
• Head on view with bags mounted

Step 7 - Doohickey Replacement (ask me in person, and I'll tell you how I almost killed my KLR during this process)

• Outer Cover removed
• Pulling the flywheel
• Parts all over the place
• New Doohickey and Spring
• Button her back up

Step 8 - Last of the little additions

• Stronger Shift Lever
• Rear Brake Bracket and Guard
• Stainless Steel Bolts...all over the place

Step 9 - Day-Long Saddle

• Saddle from the side
• Saddle from the rear

Step 10 - Electric Vest and accessory plug wiring

• Chili Vest Controller location
• Heated Vest BMW plug - on sidestand switch cover
• Accessory plug - opposite the Hot Grip switch

Current Status: DONE! On to the testing phase!!

First Ride with Mods:  February 20th was a warm day....read about it here