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KLR Mods
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Happy Trails PD (Paris-Dakar) Nerf Bars. Protects radiator shrouds and radiator in case of spills. Very sturdy. Adds to the the the KLR's general air of funky utilitarianism. Designed and built by Happy Trails in Boise, Idaho. There are cheaper, inferior knock-offs available, but I chose to support with my dollars the people who developed this and other products specifically for the KLR right here in the good old U.S.of A. Plus, Tim Bernard at Happy Trails actually backs his products, a novel idea in this day and age. Good luck trying to get after sale support for your chinese-made knock-offs.
Ok, all that being true, a popular alternative to the PD Nerf bars are the IMS mil-spec gas tanks. The almost 7 gallon tank is so large that it's shouds protect the radiator as well as the Nerf Bars do, and you get more fuel capacity than with the stock tank. The IMS tank is also cheaper than the PD Nerf Bars. You cannot use the IMS tank with the PD Nerfs--it's one or the other. There may be some issues with the legality of the IMS tank on-road in your locality, and it does have some quirks regarding gas caps, tankbags and gas leaching through the plastic. As with any modification, research carefully online before buying to make sure it's right for you. Personally, I really like the PD Nerf Bars, and I like doing business with Happy Trails. Makes me feel good that we can still design and build good stuff here in the U.S. and deliver good service.
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Happy Trails Original Side Racks. Prevents scratches to sidecovers when using soft saddlebags. Also keeps bag from pushing sidecover into hot muffler. These look good, worked well and and also provide a handhold when hoisting the bike onto the centerstand. If you are absolutely sure you won't want to add hard luggage, these are great. If you might want to go to hard panniers in the future take a look at the Happy Trails SU racks, which can be used with some the Ortlieb clip-on soft bags as well as with aluminum hard bags. The SU racks are very popular with KLR riders because of their versatility. I like soft luggage because it's safer in a fall, and because the security advantage of hard bags is limited on a trip--you generally will have a tank bag, tail bag and perhaps tank panniers which will like all be cloth, so there are still plenty of opportunities for thieves even with hard saddlebags. I keep my money and camera on me, and generally park where I can see the bike. Lockable hard bags are a much bigger value in town than on long distance trips.
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The infamous KLR "doohickey"--counter balancer adjustment lever. The stock piece disintegrates about, oh...15 to 20% of the time. Subsequent catastrophic engine failure is a possibility. However, after years of research I have only found a single credible incident of a KLR engine actually fragging from a broken doohickey. Nonetheless, now that you know about the doohickey, you too are hexed and must replace it with this finely machined unit from Eagle Mike available at Arrowhead Motorsports. Otherwise you are certain become the only person to ever become stranded in the remotest part of the Yukon by a broken doohickey. Where you will no doubt be eaten by a bear. All because you were too pig headed to get with the program and replace your damn doohickey. Serves you right. ;-)
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IMS SuperStock footpegs. If you go to Alaska, you will get rained on and you will be walking in mud. You really don't want to support your muddy boots on slick, wet, rubber footpegs, do you? These cleated IMS pegs will do a much better job of keeping your feet in place, but won't tear up the soles of your boots like some models with sharp teeth. IMS footpegs are ~$80, but a much cheaper alternative are the stock metal-toothed footpegs from the Suzuki DR650. Not as broad of a platform, but perfectly grippy and a fraction of the cost of the IMS pegs.
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Master brake cylinder guard. Attractive farkle protects master cylinder from those wild flying rocks.
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Brushed aluminum muffler heatshield from Dual Star. Like most things at Dual Star, well-made but pricey. When used in combination with the HT side racks, probably superfluous. Looks cool, though ;)
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Centerstand. Good for making it easier to lubricate chain, but not really good for much else. Reduces ground clearance, and has been known to cause footpeg bolts to fail in some off road situations. Seems an ok addition to a primarily on road bike, but a pretty questionable mod in my view for true dual sport riding. Tim Bernard at Happy Trails was kind enough to drill the new bolts for me, and I had them safety wired on to reduce the chance of losing a footpeg. I was glad I had a centerstand when I had experienced a flat tire. Since I'm an adventure tourer, and not not a true dirt/off road rider I find the centerstand a worthwhile mod. The more rugged and rocky the surface you plan to ride, the less wise it is to have a centerstand on a KLR, in my opinion. This mod worked fine for me in Alaska, but I think a centerstand on a KLR would be a liability in Copper Canyon , Mexico.
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Foot kick for centerstand. Stand can be ordered with this added on at time of purchase. Foot kick greatly eases raising bike onto centerstand, especially for the inseam challenged like me.
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Crampbuster throttlerocker. This is the wide version. Allows wrist to maintain throttle pressure while grip is relaxed. Not as good as a true throttle lock, but works kinda-sorta ok. Doesn't get in the way.
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