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.
Suspension
Fork Boots
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.
Top Diameter | Bottom Diameter | Length |
42 mm | 45 mm | 60mm |
Shock Bearings & Seals
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
Swingarm
Complete kit to replace the bearings and seals in the KLR650 swingarm pivot.
Kit Contents: | |
---|---|
Seal | 4 |
Needle Bearing Shaft | 2 |
Needle Bearing | 2 |
Fork Seals & Bushings
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.
Lowering Link
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.
Some KLR models from 2004 - 2007 may have a longer shank that do not allow the bolts to tighten to the bearing. If that is the case, we recommend the addition of either a 14 mm split type lock washer or a 15 mm flat washer under the nut of both link mounting bolts.
Fork Cartridge Dampers
Damping Rod style forks are notorious for being too harsh, too mushy and too easy to bottom. Gold Valve Cartridge Emulators remedy this problem by controlling the compression damping with a tuneable valve. The Emulator sits on top of the damping rod and is held in place by the main spring.
Simply put; Emulators make damping rod forks perform like well-tuned cartridge forks. Installation and tuning for any condition or rider preference is very straight-forward.
Simple to install and completely tunable for all conditions and rider preferences.
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.
Forks
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.
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.
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.
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.
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.
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).
Will not work for 2014-Cur 'Mid-Year' New Edition 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
Not for 2014-2018 New Edition
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.
Shock
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 Moab 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.
If you have '87-'07 KLR, you MUST order a new mounting bolt. Not required for 2008-2018 models.
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.
If you have '87-'07 KLR, you MUST order new mounting bolt. Not required for 2008-2018 models.
Electrical
Here's an easy way to add a Tach to your motorcycle.
- Tachometer from 0-19,999 rpm
- Non-resettable hour meter from 0-99,999 hours
- Easily mount it to any surface using either the bolt-on (screws not included) or peel-n-stick mounting options
- "Wrench Icon" with hours
- The smallest available meter at 50 x 25 x 14mm and has large, easy to read digits
The Trail Tech Vapor Speedometer/Tachometer units are custom designed for an exact fit. They feature a bright white backlit LCD display, waterproof connections, and all parts needed for a complete installation. These units accept AC and DC power input, and automatically switch to internal power if external power is removed. Power connectors are included. Permanent solid-state memory guarantees that data is never lost, even without power. Units are available in black.
Trail Tech provides a one year warranty and unlimited free phone and email support.
Unit functions:
- Speedometer
- Current Speed
- Maximum Speed
- Selectable MPH/KMH Display
- Tachometer
- Real-Time RPM Bar Graph
- Numeric RPM Readout
- Dual Programmable Shift Lights
- Up to 20,000 RPM
- Temperature
- Ambient Temperature
- Engine Temperature (liquid cooled only, optional air cooled sensors available)
- Dual Programmable Temp Lights
- Distance
- Adjustable Distance
- Permanent Odometer
- Selectable Mile/Kilometer Display
- Clock
- Hour Meter, Stop Watch, Ride Time
- Accumulated Ride Time
- Permanent Hour Meter
Battery
Built with the latest in Lithium Ion Polymer Technology. All components are designed, manufactured, assembled and packed in one location assuring high quality and consistency. Besides extreme lightweight (50% to 70% lighter than standard lead-acid batteries) it also features a built-in LED test gauge and the ability to mount it in any position.
The Firepower features increased cranking amps over lead acid batteries and has a very fast recharge cycle, and can be brought up to a 90% charge within 6 minutes. It also has 6 to 12 times more cycle life when compared to lead acid batteries. A 2-year warranty insures that your investment is protected.
220 CCA 12V/48WH
Package Dimensions: 6.20 x 3.70 x 5.25
CDI
Designed to enhance overall performance when installing a high-flow jet kit. This CDI box enhancements include:
- Duplicator circuits
- Increased RPM redline
- Altered ignition advance curves
This unit may also be used to replace a defective CDI box on a stock machine. For 1990 - 2007 models only.
Wheels
We start with an Excel rim, Silver Warp 9 hub, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike. Optional upgrades include color anodized Warp 9 hubs or a factory Kawasaki hub and SUN rims available in 3 colors.
Our pro shop then laces and trues your wheel to perfection, giving you the highest quality custom wheel available.
- New Warp 9 billet hub or OEM hub with bearings and seals installed
- 1.60 x 21 Offroad
- 1.85 x 21 Dualsport
- 2.15 x 19 Adventure
- 2.50 x 19 Adventure (Sun rims are 2.75)
- 2.15 x 18 Street
- 3.50 x 17 Supermoto
Add a tire to your wheel order and we will throw in a tube and mount and balance it at no additional charge.
We start with an Excel rim, Silver Warp 9 hub, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike. Optional upgrades include color anodized Warp 9 hub or a factory Kawasaki hub and SUN rims available in 3 colors.
Our pro shop then laces and trues your wheel to perfection, giving you the highest quality custom wheel available.
- New silver Warp 9 or OEM hub with bearings and seals installed
- 2.50 x 17 (Sun rims are 2.75)
- 2.50 x 18 Offroad (Sun rims are 2.75)
- 4.25 x 17 Supermoto
Add a tire to your wheel order and we will throw in a tube and mount and balance it at no additional charge.
Warp 9 Supermoto wheels are built with billet hubs, 7000 series aluminum rims and laced and trued with stainless steel spokes and nipples.
- The 3.5" x 17" front wheel includes a 320mm brake rotor and caliper relocation bracket.
- The 4.25" x 17" rear wheel also comes with a rear brake rotor already mounted.
Rear Includes Sprocket Carrier with 42T Sprocket Installed. Select your color or default to hub color choice.
Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.
These wheels will NOT fit the Tengai, or 'C' model KLR
Please allow 2-3 weeks for delivery.
Cannot be canceled.
Complete set of 'Adventure' wheels. These are the same rim sizes as used by the BMW GS and other big adventure bikes. The 19" front and wide 17" rear will give you great twisty road handling on the pavement while still being dual-sport friendly.
We start with Silver Excel or Sun rims, Warp 9 billet hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.
Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.
- Warp 9 hubs with bearings and seals installed
- Excel 2.5" or Sun 2.75" x 19" front rim
- Excel or Sun 4.25" x 17" rear rim
- Buchanan's stainless steel heavy gauge spokes and zinc-plated nipples
- Optional OEM Kawasaki hubs are available
- Optional color matched billet sprocket carrier is available
Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.
Please allow 2-3 weeks for delivery.
Cannot be canceled.
We start with Silver Excel or Sun rims, Warp 9 billet hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.
Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.
- Warp 9 hubs with bearings and seals installed
- Excel or Sun 3.5" x 17" front rim
- Excel or Sun 4.25" x 17" rear rim
- Buchanan's stainless steel heavy gauge spokes and zinc-plated nipples
- Optional OEM Kawasaki hubs are available
- Optional color matched billet sprocket carrier is available
Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.
Please allow 2-3 weeks for delivery.
Cannot be canceled.
Bearings
Rear wheel bearing kit contains all of the bearings and seals required to re-fit a wheel.
Wheel bearings typically fail from water and dirt contamination. These wheel bearing were developed in partnership with KML Bearing and is designed for the difficult operating environment of the Power Sport industry.
Premium EMQ quality, hi-speed-bearing featuring low drag, double lip rubber seals which provide superior exclusion of water, dirt and to improved grease retention.
Type TC Nitrile Elastomer wheel seals are specifically designed to keep out water and dirt.
Packed with Chevron SR1-2 high-performance grease with rust and oxidation inhibitors.
The rubber coated outside diameter creates an optimum seal at the hub.
Steel garter spring guarantees constant pressure on the axle shaft over the life of the seal.
Description | QTY per Kit |
Ball Bearing | 3 |
Luggage
Luggage Racks
CycleRacks are made out of steel tubing, bent in a press, and welded together in a jig. All of their racks have the same platform, 18" wide by 12" deep. Includes lower mount hardware.
All of their products are 100% made in the USA. If the rack is ever broken for any reason, CycleRacks will replace it for free, you just pay the shipping.
- CNC laser cut from 3/16" 5052 aluminum
- Sand blasted and powder coated black (shot peened look)
- Givi Monolock and Rotopax compatible
- Turn signal protection
- Does not interfere with side rack luggage systems
- 14" (L) X 19 3/4" (W) Platform
- Oversize holes allow use of any strap, hook, rope or cargo net to secure load
- Stainless steel hardware instructions included
- Bolt on item, no modifications required!
- 100% Made in the U.S.A.
The Nomadic Rack for the early generation KLR650. CNC laser cut from 3/16" 5052 aluminum with a large 12" x 18" mounting surface area. Sand blasted and then powder coated black to give it a shot peened look. This rack is an easy installation with no modifications required. There are multiple strap slots for securing gear bags and cargo. Rack is compatible with RotoPax mount. All hardware and instructions included.
Packages available include Rack with the RotoPax Mount or if you really want it all, you can order the Rack, Mount and a Fuel or Water Container.
Drivetrain, Wheels
Polyurethane drive cushions for the KLR650. Polyurethane has a higher abrasion, cut, and tear resistance than rubber as well as much better resistance to chemical breakdown. This will offer longer life and better damping when compared to the rubber counterpart.
The KLR650 is rather hard on the cush drive rubbers. Replace these any time you feel excessive play in the sprocket hub. Excessively worn dampers can cause the cush hub bearing to fail - which will ruin your sprocket carrier.
Frame
Side Stand
A billet aluminum side-stand from PSR. This is the side-stand you want when you are using lowering-links.
Has many height settings from stock to 2" lower, a must have when lowering your bike. Available in anodized black.
Footpegs
The IMS Pro-Series foot pegs are made of stainless steel and are hard coated to prevent drooping.
They are the original Cast 17-4 Stainless steel pegs that revolutionized the foot peg market.
These pegs are 50mm(1.95") x 78mm(3.1").
Steering Bearing
Tapered roller bearings provide decreased maintenance, less wear, smoother operation and longer life.
This set of high quality replacement steering stem bearings includes:
- Upper and lower tapered bearings
- Upper and lower bearing races
- Upper and lower seals
Brakes, $25 and Under
Pads
Replacement retaining pins for the brake caliper. Includes 2 stock style brake pins.
Be sure to use some anti-seize on the threads when you install them.
Rear caliper only for DR350 and DR650.
Armor - Bike Protection
Handguard
Mount Barkbusters standard aluminum bar handguards to 1-1/8" motorcycle handlebars with the Barkbusters Tapered handlebar saddle clamp set.
What's in the box:
- 4 peice saddle clamp set
- 2 complete saddles
These are all you need to mount your current Barkbusters Handguards when you upgrade to a tapered oversized 1 1/8" handlebar.
Provide protection for your motorcycle’s front brake and clutch levers with Barkbusters aluminum bar lever protection handguards. Model Specific, these guards feature heat treated full wrap aluminum backbones that mount at two points on each side for strength. Prevent costly damage to your motorcycle with Barkbusters aluminum bar lever protection handguards.
Features:
- Two mounting points provide secure protection
- Full wrap guards
- Heat treated aluminum backbone bars
- Easy installation
- Compatible with all Barkbusters deflector guards (not included)
Add Plastic Handguards for a complete kit.
Skid Plate
- Protect vital engine parts and cases from rocks and debris
- Clear anodized for corrosion protection and good looks
- Skid plates made from 3/16" 5052 H-32 aluminum
- Smooth underside won't snag when crossing logs
- Oil drain hole on all required models
- Heat-treated chromoly steel clamps keep plates mounted securely
- All mounting hardware included
Lighting
Headlight, Bulb
This is a standard H4 bulb that has a 80 watt low beam and a 100 watt high beam. This is an easy lighting upgrade that should not over tax a stock charging system.
Turn Signal
The SignalMinder unit is designed as a plug-in accessory for many Japanese bikes. SignalMinder uses a microprocessor to cancel the turn signals at one of three selectable time outs; 10, 20 or 30 seconds.
You can also make it so that all four of your signal lights also act as running lights and establish a dual-channel system on your bike. With the dual-channel system, when you activate the RIGHT turn signal three times in succession, you get 4-way hazard flash lights.
Connecting the 12 volt supply from the brakes to the SignalMinder, also allows for a brake flash option.
There are many options and configurations using this electronic tool.
No wire cutting required. The kit includes Scotchlok connectors to tap into existing wires.
Brakes
Caliper Rebuild Kit
Master Cylinder Rebuild Kit
All the parts you need to freshen up your brake master cylinder. New piston, seals, return spring, boot and snap ring.
Made by Nissin, an OEM supplier in Japan
All the parts you need to freshen up your brake master cylinder. New piston, seals, return spring, boot and snap ring.
Made by Nissin, an OEM supplier in Japan
- Kit contains all of the components to re-seal leaking master cylinders
- Includes replacement hard anodized aluminum piston, replacement cover screws, boot and spring
Rotor
- Heat-treated and tempered stainless steel construction
- New design rotor profile delivers improved brake performance and is self-cleaning
- Weigh less than the OE rotors and look great
Fuel and Intake
Air Filter
FunnelWeb ProLine Filter Highlights:
- Optimum air flow for increased riding time
- Improved engine protection
- Extended filter change intervals
- Simple to install, clean and re-oil
- Easy fitment
Like all FunnelWeb filters, the ProLine Filter features profile cut, single layer, single density foam that doubles the external surface area of the filter without increasing the original filter size. The ProLine Filter traps dirt, dust, sand and mud over a larger area on its outer surface, ensuring optimal air flow is maintained for maximized engine performance and reliability.
The single layer, single density polyurethane foam has the added advantage of being easy to clean and the ability to maintain its original shape after numerous washes. Overall, compared with conventional foam filters, FunnelWeb offers more protection from dirt ingestion, has longer service intervals and maintains high airflow rates when dirty.
Dual stage foam: 2 different pore sizes create more trapping area for even the smallest dust particles. Flame laminated foam: Both "Stages" are not glued but heat sealed to provide maximum air flow. Light color foam makes it easier to see where the filter oil has covered and where it has not.
- Made of flame-laminated dual-layer foam, bonded with the highest quality glue to stand up to the roughest and toughest of any style of riding or terrain
- This filter, used with No Toil foam filter treatment, provides the best air filtration system in the world
- Fully open-cell structure for highest airflow and maximum protection
- Heavy-duty glue provides protection from all solvents
- Wide soft sealing ring for extra protection
- Flexible seams prevent cracking
- Original OEM size
Twin Air's patented design, high quality materials and superior construction deliver unbeatable performance and protection - and make Twin Air Filters the hands-down choice of more World and National Champions than all other filters combined.
An air filter is your engine's only protection against the elements, and your stock filter isn't up to the task. Replace it with a Twin Air - the #1 filter system proven on motocross tracks around the world.
Twin Air's fused layers of open-pore foam and fine inner foam trap even the smallest particles-without restricting airflow.
- Unique triple stage foam filter designed for the most extreme conditions
- Eliminates the need for power robbing dust covers and outerwear covers
- Increased protection against silt, water, and sand
- Allows for extended filter service intervals
- Can be cleaned, re-oiled, and re-used like a 2 stage filter
- Used by factory off road teams around the world
- Increased air flow over the stock air filter
- Designed to increase horsepower and throttle response
- Easily fits inside the factory air box
- Larger surface area over foam filters which offers longer service intervals in dusty conditions
- Four layers of premium cotton gauze provides outstanding filtration
- Washable & re-usable, never wears out
- One filter will last the lifetime of your bike
Have you lost or broken the stock air filter cage for your KLR? Maybe you need a spare? Here it is, the OEM cage that will fit any of the foam air filters on this page. This kit includes the cage and the mounting hardware.
Jet Kit
Our own jet kit for the Mikuni TM40 carburetor.
Includes new main jets, pilot jets and a new needle with e-clip.
Comes with a printed Mikuni tuning manual and a jetting suggestion chart.
Not for the stock carburetor Fits TM40 conversions Only
Designed for use with stock engines using either stock or aftermarket exhaust and air filters.
- Provides a simple and affordable solution to carburetor tuning problems.
- Allows you to tune your bike for increased power and smoothness while retaining fuel economy.
- Includes a guide on how to install and use your jet kit to it's full potential.
- For a top quality installation we recommend adding an extended fuel screw and a set of replacement carb screws.
This kit includes 2 Needles that have been developed by JD Jetting and manufactured for them to their exacting specifications. These two needles allow a wide range of tuning possibilities and provide correct fuel delivery at any throttle position.
4 allen type screws for the float bowl are also enclosed should you strip out the stock screws during your tuning process. Complete instructions with photos, jetting suggestions for different set-ups and situations, 5 Main Jets and a drill bit complete the package.
Carburetor Repair Kit
Carburetor
Strip out the bowl screws on your KLR? Carb top screws get rusty? Here is a set of 4 allen screws and lock washers for the bowl and 4 allens and flat washers for the vacuum top.
Replacement socket head (Allen) screws in case you strip out the stock JIS heads on your TM40 bowl. The originals can be stripped out when doing any tuning or carburetor maintenance. Sold in a pack of four, all for the bowl.
Seats
Complete Seat
Seat Concepts seats are constructed using a foam material that is higher quality than OEM seat foam. Their proprietary formula is plush, while still offering the necessary amount of support. Their unique comfort and shape maintains a similar contour to stock at the front of the seat so the rider’s legs are not spread farther apart, but tapers out towards the mid-point to distribute rider weight over a greater area.
These great features combine to offer you a custom seat feel, and provide greater enjoyment and increased range for long commutes, or Dual-Sport rides!
The Complete Seats come assembled with an high quslity aftermarket pan and ready to ride.
Width: | 12 5/8" (321mm) |
Height: | Same as OEM |
The Commuter seat maintains a similar contour to stock at the front of the seat so the rider’s legs are not spread farther apart, but has a dished seating position towards the mid-point to distribute rider weight over a greater area. This dished area is also wider than the stock seat to increase support. The passenger platform is the stock shape.
The Commuter seat is the best choice for extended pavement riding and mellow offroad. The unique shape and added width will provide greater enjoyment and increased range on a long commute, or Dual-Sport ride!
Seat Concepts seats are constructed using a foam material that is a much higher quality than OEM seat foam. Their proprietary formula is plush, while still offering the necessary amount of support. Their unique comfort and shape maintains a similar contour to stock at the front of the seat so the rider’s legs are not spread farther apart, but tapers out towards the mid-point to distribute rider weight over a greater area.
These great features combine to offer you a custom seat feel, and provide greater enjoyment and increased range for long commutes, or Dual-Sport rides!
The Complete Seats come assembled with an high quality aftermarket pan and ready to ride.
Fits Model/Years:
2022-24 KLR650, S, ABS, TRAVELER, ADVENTURE
Width: | 12 3/4" (324mm) |
Height: | Same as OEM *2023 KLR650S (1.25"/ 32mm Taller than stock) |
Corbin seats are carefully designed to provide a comfortable riding position. They are firm and supportive which allows you to ride all day without fatigue unlike the stock seat. Comfort Cell Foam retains resilience and doesn't crush down like the stock seat foam. On the top, Corbin covers are only the highest grade of weather resistant materials for durability and long life. Corbin seats install the same as similar to stock with two bolts into the chassis which provides a closer fit to the bodywork and tank.
Body
Windscreen
Transform your ride. MadStad's patented mounting system allows riders to adjust the height and angle of their motorcycle windshield resulting in much smoother airflow, better wind protection and a more comfortable ride than any fixed windshield can provide.
What's included and what's not included in the kit:
Their complete drop-in system is custom-made for your bike and includes everything needed to mount and position the shield.
Your bike will not require any modification.
- Black hardened acrylic base plate and mounting hardware
- A set of MadStad adjustable brackets
- Rear support brackets
- 3/16" (4.5 mm) thick cast acrylic windshield
The MadStad adjustable brackets sit out in front of your fairing on black fly screen which attaches in place of the factory shield. With the windshield now separated from the front of the bike and the fly screen helping to deflect wind up from underneath, you have total control over the shield height, angle and airflow. This lets you dial in a smooth ride and quieter cockpit far better than any fixed windshield can provide.
The Windscreens and Deflectors are made from 2.0mm Quantum® hardcoated polycarbonate, and the Windscreens are offered with either a plain edge or an E43R EU-compliant beaded edge. This high quality material, along with state-of-the-art manufacturing techniques, provides outstanding clarity, impact strength and scratch resistance unmatched by any windscreen maker worldwide. Quantum hardcoated polycarbonate is the material of choice for serious motorcycle riders. It is 10X more abrasion resistant than FMR hardcoated polycarbonate, and 30X more than windscreens made from commonly used acrylic or "aircraft plastic”. VStream gets its name from its unique patented shape. The advanced “V” profile and dimensional contours push the wind vortex out and away from the rider's helmet, resulting in a peaceful, quieter riding environment. VStream Windscreens are easy to install and are protected by a 3-Year Warranty against breakage!
Features:
- Fairing-mount VStream® Windscreens are designed specifically for each make and model to ensure optimum performance and perfect fit using the OEM mounting hardware.
Center Screen Height: 13.38" (34.0cm)
Width: 12.50" (31.8cm)
Center Screen Height is from the bottom center edge to top of screen. Width is measured in a straight line across the back at the widest point.
Exhaust
Muffler
The Powercore 4 spark arrestor muffler. FMF developed the Powercore 4 to increase the horsepower and torque throughout the entire power curve. Highest quality packing for long life. Removable spark arrestor included. Louder than the Q4. Approximately 99db stock or about 94db with optional Quiet Insert installed.
- Uses long-life muffler packing for increased packing life
- Forest Service approved spark arrester
Delayed stock from manufacturer, please ask for availability.
- The Q4 employs intricate chambers, baffles and proprietary multistage packing material making it the best performing quiet muffler available
- Constructed from aircraft grade aluminum and high strength stainless steel
- Sound rating 96dB
- Much lighter than the stock muffler
Headpipe
The FMF Powerbomb is a four stroke header pipe unit that has a unique bulge precisely located in the header system. A "pre-muffler" of sorts, the Power Bomb actually lowers sound output because it creates more surface area to absorb the sound medium (exhaust). The surface area of the perforated core lets the sound exit into the absorbing material (steel wool packing) and then allows the air to expand, cool and ramp back up with the higher pressure air. The result? The FMF Powerbomb is instrumental in reducing the decibel level on any four stroke and because of the expansion and contraction on exhaust through the system, the flow has been increased by nearly 10%. That means more power throughout the range.
Features:
- Tuned for bottom to mid performance
- Powerbomb headers are the front runner in performance headers
- Designed for full service access to oil filter
Gasket
This is a new gasket for the cylinder head - head pipe junction. Installing a new one with your new header will ensure a good seal and no exhaust leak.
Communications & Nav
GPS
Voyager Pro, The Connected Rider’s GPS. Trail Tech offers a variety of model specific and universal kits for complete vehicle integration. All kits include mounting hardware, tach sensor, and power connection. Temperature and wheel sensors vary by kit, see kit contents for details. Adventure Begins Here!
Trail Tech provides a one year warranty and unlimited free phone and email support.
- Trail Tech Voyager Pro, the Connected Rider’s GPS. A premium off-road GPS with 4 inch color touchscreen anti-glare display, sealed and rated IP67 for anti dust/water intrusion
- The map screen is enabled with base maps, topography lines, hill shading, and some trails. Record or load GPX trails and riding areas, and transfer to a PC using the MicroSD card. Voyager Pro comes loaded with North American maps, but other map regions can be downloaded for free.
- Amongst the major features is Buddy Tracking. Buddy Tracking uses localized radio signals and can support up to 20 riders in a single group. View members of your ride group on the map screen in real time, increase your following distances, and use the buddy beacon to summon your buddies. Cell reception is not required.
- Buddy tracking displays the current location of up to 20 members of your ride group on the map screen
- Voyager Pro is Bluetooth enabled for intercom, phone and media controls. Play songs from your phone or MicroSD card using a Bluetooth headset, speaker, or intercom. Two phones and two headsets can be connected at the same time.
- The 4 inch glove friendly color touchscreen TFT display is visible in all conditions, including direct sunlight. Sealed and rated IP67 for anti-dust and water intrusion, it is built to withstand the harshest elements that come with extreme riding conditions. The mounting dock hard mounts to the dashboard, can be locked, and allows for quick removal of Voyager Pro from the machine. The dock utilizes the AMPs hole pattern, and is compatible with the full line of RAM brand mounts or Trail Tech mounting hardware.
- Voyager Pro integrates with your vehicle using standard Trail Tech vehicle sensors, providing vital ride data such as engine temperature, RPM, battery voltage, speed/distance and more.
- At 5.6 x 3.5 inches, Voyager Pro still fits on dirt bike dashboards, but is big enough to use on adventure bikes and UTVs. Voyager Pro’s mapping abilities and buddy tracking make it the premium choice for off-road riders.
Engine
Higher pressure in the cooling system, raises the coolant boiling point and increases protection from coolant loss due to overheating.
23 PSI - 1.6 Bar.
A high quality torsion spring puts more consistent force on the tensioner lever. Requires drilling a small hole in the case to seat the spring. Drill bit included.
Eagle Manufacturing balancer lever kit, featuring top-quality components.
The Eagle Manufacturing idle-shaft lever and spring is designed to replace the less durable stock unit. The one-piece lever is precision machined from 17-4PH hardened stainless steel, ensuring exceptional strength. The kit also includes a stainless doohickey and a torsion spring with a drill bit, replacing the previous extension springs with a superior torsion spring for enhanced durability.
A direct replacement for the stock KLR hoses that tend to crack and leak after a few years.
These silicone hoses are custom made for us. Silicon hoses operate at much higher temperatures and pressures than other rubbers, they don't perish, and they look great!
Our very own version of the popular thermostat bypass for the KLR. Gives faster warm up and more constant engine temperatures. Eliminates the wildly fluctuating engine temperature gauge. A more controlled and constant temperature is easier on your piston and cylinder and may prevent or reduce oil consumption. We use a 180 degree thermostat instead of the stock (too cold!) 160 degree unit. Warmer coolant temperature promotes better fuel vaporization and can increase fuel economy.
Our bypass system mounts the new thermostat in a small billet extension housing right where the stock thermostat is now. There is no bulky external housing to hang off the motor. The bypass hose tees in to the lower radiator hose using a length of quality high temperature silicone hose. It all makes for a clean simple installation.
The complete Thermo Control package - Our in-house designed Thermostat Bypass kit, a set of Custom Silicone Hoses and a Hi-Pressure Radiator Cap. All combined to help your KLR cooling system be at the top of its game. The Thermostat Bypass kit includes a thermostat with a higher temperature rating that will keep the motor more in its happy spot.
The Silicone hoses are stronger than the stock rubber units and will better resist cracking and leaking.
Clutch
Complete set of friction plates, HD springs and steel separator plates prevent premature driven plate wear, oil muddying and loss of stack height. Built with swaged aluminum carriers that spread the load on the clutch basket and prevent clutch basket "dogging". Anti-swell, alloy impregnated heavy-duty cork-based facings for smooth clutch take-up. Allows modulation, unlike paper clutches which tend to snatch.
The Rekluse EXP employs the same EXP assembly as their premier product; the difference is that it fits into your stock clutch assembly, saving you money! Now you can enjoy the benefits of Rekluse auto-clutch technology on your KLR.
An auto-clutch automatically feeds out the engagement of the clutch using centrifugal force. This allows you to start and stop without touching the clutch lever. The automatic feed is fully adjustable to suit the rider's needs while retaining full manual override with the clutch lever. This automatic feed delivers easier on/off throttle transitions, improved traction, better control, and more confidence.
Gasket
Generator cover gasket to seal up the cover once you have your new Doohickey in place. New OEM gasket. What else can we say? If in doubt, put in a new one.
Put fresh O-rings on your KLR when you do your next oil change. Here you have new ones for the Oil Filler and the Oil Filter Housing Cover.
Replacing your clutch or removing that side cover for any reason? You are going to need a new gasket for the cover to ensure a leak-free assembly.
Valves
K&L® shims exceed the maximum of the Apparent Rockwell Hardness "C" scale. Shims average 47.0 compared to the 46.0 maximum.
This kit fits KLR650 87-18 as well as other brands and models , please verify correct size for your model before purchase.
29mm diameter - Includes two valve shims of each size 2.30, 2.40, 2.50, 2.55, 2.60, 2.70, 2.80, 2.90, 3.00 and 3.10. In a shim box.
20 shims in total. From K&L.
BMW / KAWASAKI / YAMAHA
Cam
A pair of stage 2 intake and exhaust 'drop-in' camshafts. Great mid-range and top-end increase. Uses stock valve springs. Modifying the airbox and rejetting will be required to realize power improvements with these cams. These are new billet cams - No core return required!
Drain Plug
Stock and typical after market drain plugs can protrude past some skid plates. This steel low profile drain plug stays inside the skid plate so it can't be snagged by passing objects.
Comes with 4 crush washers.
Oil Filter
Providing unbeatable performance and exceptional value, Hiflofiltro is the best-selling brand of aftermarket filters for motorcycles, scooters, and ATVs worldwide. The filters are also supplied to original equipment manufacturers as well as private label brands.
You pay $3.59 per filter with our value 5-pack!
Superior Filtration:
This should be the last oil filter you will ever buy. Made from laser cut, medical grade, 304 stainless steel micronic filter cloth, this filter provides 200% more filter area in many cases. Most good paper filters will pass particles in the 90 to 95 micron range, and some tested, as much as 300 microns. Sand is about 125 microns and a white blood cell approximately 25 microns. Flo's stainless filter catches items down to 35 microns "absolute", which is about 3 times better than most good paper or brass filters. The pleat seam is welded, able to withstand up to 600 degrees in our filter, not glued, like paper filters.
Controls
Grips
- Machined and knurled 6061 billet aluminum. Actual color may vary
- Removable end cap for easy hand guard installation
- Works with standard housing
Levers
New from Twin Air, a forged aluminum KLR650 folding shift lever with your choice of Black, Blue, or Green tip. These are 3/4" longer than the stock lever which makes for easier shifting while standing, as well as for those with a larger boot size.
Drivetrain
Chain Guide
Sprocket
Individual 14T, 15T or 16T front sprockets.
JT Sprockets are made from the latest generation of computer design and control metal cutting equipment for maximum durability. Front sprockets are made from chromoly SCM420 steel alloy. All sprockets are heat-treated and hand-finished to meet or exceed the highest possible quality standards.
Quality steel sprockets and EK SRO6 O-ring chain. We put them together to make a complete, affordable kit. Chain comes with clip type master link.
Gas Tanks
Petcock
Does your stock vacuum operated petcock not shut off when your bike is parked? Replace your stock vacuum operated petcock with this manual one. Must be shut off any time the bike is parked for more than a few hours. Fits stock or aftermarket tanks.
Aftermarket plastic tanks might need the hole cut into an oval shape to fit the two standpipes.
Drivetrain, $25 and Under
A pack of 10 Fuji style lock nuts to put on the sprocket of your KLR650. These are an 8 mm, flanged type nut that will keep your sprocket snug and tight.
Engine, Tools
Repair Manuals
Clymer repair manuals provides step-by-step procedures based upon the complete disassembly of the motorcycle. This hands-on experience combined with extensive research results in a manual that is both user-friendly and detailed. Contains hundreds of original photos, exploded views, drawings, specifications and charts to illustrate each job. Also features shortcut repairs and high-performance modifications.
Whether you're interested in routine maintenance tasks, troubleshooting, or more extensive repairs, the in-depth coverage provides indispensable information about your KLR650.
Engine & Maintenance
Your automatic cam chain tensioner is spring loaded. This can make it difficult to install as it wants to extend before you have it bolted into place. This handy tool will back off the cam chain tensioner mechanism and hold it for you. No more awkward 3-handed contortions are required to get the tensioner installed.
Engine, $25 and Under
Drain Plug
A 10-pack of drain plug sealing crush washers. Replace your sealing washer at every oil change to prevent a leak.
Extra protection for your motor! Strong magnet at the end of the plug picks up metallic flakes in your oil, protecting your engine!
Suspension, Tools
Fork Seals & Bushings, Suspension
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