KLR650: Suspension

Cogent Drop-in Dynamic Cartridges will vastly improve both the compression and rebound damping of your stock forks. Designed by Rick at Cogent Dynamics on his high-tech suspension dyno, then tested and endorsed by KLR owners all over, these units have been given the seal of approval by the ProCycle staff for both performance and ease of installation. No disassembly of your forks, no drilling of damper rods. Just change the oil over to 5w and install the units under the springs and hit the trails.

If you weigh up to 250 pounds, select the .64 spring kit. If you are over 250 or carry lots of luggage, please select the .70 spring kit. Please call if you have any further questions.

All of these kits include DDCs, springs, fork oil and preload spacers.

The complete fork upgrade kit - Progressive Suspension springs and Race Tech emulators. Also includes a set of top quality fork seals and fork oil to complete the job. Everything you need to transform your mushy stock forks into suspension that really works.

A dual-rate fork spring for the early KLR650. These springs start with a .40 kg/mm winding and after approximately 20% of the stroke, stiffen up to .60 kg/mm for the remainder of the travel. A very nice improvement over the stock springs which are .40 kg/mm for the entire travel.

Developed by the KLR suspenison experts at Cogent, this set of springs will stiffen up that wimpy KLR front end. Choose between .64 kg/mm springs (60% stiffer than stock) or .70 kg/mm units (75% stiffer than stock).

Progressive springs offer a soft initial spring rate for a plush ride. Progressively wound design provides increased resistance to bottoming as spring compresses. These springs are significantly stiffer than the wimpy stock springs.

They will make a big improvement in the front forks while still delivering a smooth ride. Sold in pairs.

Race Tech has developed these fork springs specifically for the heavier weight of the KLR650.
Sold in pairs.

• The .43 springs are 7% stiffer than stock and will be a great choice for most riders
• The .48 springs are 17% stiffer than stock and will be a better choice for heavier riders
• The .52 springs are 30% stiffer than stock and will be a good choice for loaded adventure bikes or very aggressive riders

These will not fit the Tengai model.

Race Tech has developed these fork springs specifically for the heavier weight of the KLR650.

Sold in pairs.

• The .70 springs are 75% stiffer than stock and will be a great choice for most riders
• The .80 springs are 100% stiffer than stock and will be a better choice for heavier riders

These Cogent Drop-in Dynamic Cartridges will vastly improve both the compression and rebound damping of your stock forks. These units have been given the seal of approval by the ProCycle staff for both performance and ease of installation. No disassembly of your forks, no drilling of damper rods. Just change the oil over to 5w and install the DDCs under the springs and hit the trails.

Stiffer fork springs are recommended to get the full potential of the DDCs.

You can adjust the preload on your KLR shock easily, why not on the forks as well? These caps give you the capability to adjust the spring preload in your forks to match your load.

Enjoy improved front end control and ride comfort by converting the archaic dual Damper rod forks to true high performance monotube cartridge dampers. This kit contains a pair of high performance, Gas charged monotube fork cartridges complete with a set of our KLR proven fork springs. Direct internal component replacement for all 2008 to current KLR650 models. No modification to your forks are required.

• Improved resistance to front brake dive.
• Improved front end stability & cornering.
• Improved bottoming control.
• Lifetime limited warranty.
• The VERY BEST in dual sport suspension performance!

Race Tech Cartridge Emulators make damping rod forks perform like well-tuned cartridge forks. Emulators are tunable valves that sit inside your forks on top of the damping rods and are held in place by the fork springs. Simple to install and completely tunable for all conditions and rider preferences.

Patented inertia activated damping for damper rod front forks. This is the only product on the market that is smart enough to know if the wheel is trying to move or if the chassis is trying to move. We give you the best of worlds, a more stable chassis and a faster wheel response over bumps. This product will transform the front of your KLR650.

The Intiminator sits on top of your stock damper rod forcing the oil through high quality deflected discs found in top of the line shock absorbers. When the front tire hits a bump then the inertia of that bump opens the inertia valve instantly allowing for a faster response.

Installation is easy. Drain the fork oil, remove the spring, drop in the Intiminator, refill with 5W fork oil reinstall the spring and away you go.

Both kits include all bushings, snap rings, and washers.

Gen 2 kit also includes the necessary O-rings.

Gen 1 kits are OEM bushings, snap rings and washers.

Low friction 'triple lip' seal design. Oil seals last 3-4 times longer that OEM seals. Kit includes 2 Fork Seals and 2 Dust Wipers.

An excellent replacement for the stock fork boots. These are great for protection from dirt, rocks and other contaminants. These boots utilize the latest advances in material technology to adapt to fork and styling demands. These high quality fork boots are 1/4 the price of the OEM factory replacements.

Choose black, blue, red or yellow.

Fork brace precision machined from aluminum barstock. Drilled and tapped for optional lower fender attachment.

Hard anodized black for corrosion protection. Fits OEM forks. Split design allows for installing in minutes without having to remove the forks.

SuperBrace is the leading motorcycle fork stabilizer. This patented brace provides better stability, superior aerodynamics and a more streamlined look than other multi-piece braces on the market.

• Reduces low and high speed wobbles
• Improves stability in tight cornering
• Improves tire life and reduces cupping
• Decreases sensitivity to rough road surfaces and rain grooves
• Each SuperBrace is designed and manufactured for each specific motorcycle and made of 6061-T6 aircraft aluminum
• Ten minute easy installation

Helps protect vulnerable fork tube and seal from dust, dirt, and corrosive elements. Hook & loop (Velcro) fastening on back side makes installation or removal for cleaning a breeze.

The Moab Pro-Series shock from Cogent Dynamics is the standard by which all other shocks are judged in the KLR world. With its superior performance and exceptional reliability, Moab Pro-Series shocks have literally conquered the world many times over. The staff at Cogent is as passionate about motorcycles as you are.

Spring duties are handled by a custom spring available in either Standard or Heavy-Duty weights. The Standard spring will be fine if you are under 250 pounds and don't ride with luggage or passengers often. If you regularly carry luggage boxes and/or a passenger and weigh over 250 pounds, you will probably prefer the Heavy-Duty spring. Call if you have any questions.

Because of the limited space with the reservoir, adjusting your preload is just about impossible and for that reason we only sell these units with the Cogent Hydraulic Preload Adjuster already installed!

For a true comfort and performance package, we highly recommend upgrading your front suspension at the same time.

The Moab shock from Cogent Dynamics will change how you feel about your KLR. You may like it now, maybe even like it a lot, but you will absolutely fall in love with it once you mount up a Maob shock.

Spring duties are handled by a custom spring available in either Standard or Heavy-Duty weights. The Standard spring will be fine if you are under 250 pounds and don't ride with luggage or passengers often. Ride heavily loaded or with a passenger regularly and you will probably want the Heavy-Duty spring.

For a true comfort and performance package, we highly recommend upgrading your front suspension at the same time.

Progressive 465 Series Rear Shock

• Completely rebuildable
• 465 Series high-performance shocks eliminate the need for a remote reservoir by utilizing an internal nitrogen bladder.
• Five-position externally adjustable rebound damping allows you to dial in the ride you want.
• Speed-sensitive, multi-stage damping gives consistent ride over varying road surfaces
• Shock body is machined from aircraft-quality aluminum.
• Two heights to choose from. Lower your KLR an inch at the seat, or keep the stock height.

For a top notch rebuild or re-valve of your rear shock use this high quality replacement seal head.

• Complete assembly, ready to install into the shock body
• Has air bleed holes to help remove air from the oil reservoir during installation
• Double-lip oil seal design keeps out dirt and keeps friction low
• Kits include aluminum body, dust seal, bushing, oil seal, O-ring, internal guide bushing/washer, snap ring, and top-out bumper

Complete kit to replace the bearings and seals in the KLR650 swingarm pivot.

Billet aluminum lowering links. Lowers the rear suspension approximately 1 to 2 inches depending on application.

*Important when lowering the rear suspension you want to raise the fork tubes in the clamps an equal amount of inches that the rear is being lowered. That way your bike will sit level when done.

Note: We only recommend the 2" lowering links for lighter non-aggressive riders as they allow the tire to rub when near bottoming.

Disclaimer: Lowering the front and/or rear of your motorcycle will change the geometry and may affect the handling, use caution after making changes/adjustments.

Based on the wildly popular Race Tech Suspension Seminars taught by Paul Thede around the world, this step-by-step guide shows riders how to make their bikes handle like the pros. Thede gives the lowdown on all types of suspension, including cartridge and non-cartridge forks as well as dual-chamber and nitrogen-charged shocks.

The three forces of suspension, testing procedures, even the black arts of chassis geometry: Thede explains it all. The book provides step-by-step photos of suspension disassembly and assembly as well as a detailed troubleshooting guide for dirt, street and track.

Use this installation tool from Cogent to be sure that your Cogent Drop-in Dynamic Cartridges are installed correctly. A strong magnet in the end holds the cartridge firmly while you lower it into your fork leg. Then slide the spring over the tool until it holds the DDC down, then gently remove the tool. That simple. Never again question if it is properly seated on the damper rod.

Works equally well for removal when you need to change your fork oil. Also works great with Race Tech Emulators.

Innovative design makes tool easier and more secure to use than old fashioned pin-aligned drivers

• Knurled anodized aluminum locking ring
• Perfectly weighted to drive seals
• Carbon steel body halves

Showa removed the schrader valve on many newer rear shocks. Now you need a needle to recharge your shock with nitrogen after a rebuild. Race Tech built this unit just for that job.

The features of this tool include 300 psi capacity, bleeder valve and T-handle plunger pin chuck. Swivel chuck has a 12" flexible hose. Comes complete with instructions, carrying box and Schrader valve extension (required on some Showa shocks). Nitrogen bottles available at any welding supply house.

Makes installation of your linkage bearings much easier. Also simplifies maintenance of those bearings.

• Allows placing bearing needles on bearing race while greasing linkage bearings