I just bought a 2004 today that is beat to heck. I love everything you’ve done to yours, and would love to get a parts list! I am 47 and this is my first bike, and I don’t even know where to begin… Lol
my uncle just uncovered an old 2004 cosmetically beat up klr with 7000 km on the clock. its a gem i love it. its going to be so much work but so worth it. its pink because of the plastics ahahaha
Bought a 2005 this morning, the previous owner left all his accessories on the bike, wider footpegs, spot lights, crash bars, higher windscreen, 2008 front fender conversion, basically I'm pumped, can't wait, sold my dl650 v-strom a couple of months ago, it was a very good bike, but I'm more a carburetor guy, not much can go wrong with the KLR
The stock brakes were a problem for me as my other bike was a baby ninja with sintered brake pads. I waa off of for almost two month and on the KLR as my daily commute until I got caught up on maintenaince. I started of to work with a cold high idle, and a freshly sealed parking lot covered with dew. I grabbed a KLR handful of brake and was on my arse in a heartbeat. I also had reversed my baby ninja
Awesome bike :) just picked up a 2004 for a bargain and cant wait to start to make it my own :) its in the shop atm getting a roadworthy and im so pumped to get it home so i can start riding it, iv been trying to decide what color to paint it as the plastics are looking its age and i must say White looks mint :) its been 1 year since you done this video! still happy with the bike ?
Nice! Ya the bikes been awesome, basically the same since this video but I did swap out the Progressive rear shock and went with a Cogent shock which I like a lot.
You've done a lot of mods. I've go the progressive springs and race-tech emulators, but not put them in yet. I really like those crash bars. You're ready to go to the ends of the Earth. Let me know when you leave and I'll ride with you :)
@@illyadmark3223 rustoleum premium paint for metals and plastics in a rattle can. Gotta clean and scuff the plastics thoroughly before painting so the paint won’t flake off over time.
@@12lionwhelps71 it’s simple, cheap, reliable and capable, excels at nothing but is sufficient at everything. And personally I find it to be one of the most comfortable and best handling bikes when set up correctly. I try to avoid the highway and chaotic traffic so I stay on 55mph and under roads most of the time even it takes a little longer and for that type of riding, mixed with Michigan potholes and rutted out gravel roads, the KLR is king.
Cool build. I got a 2018 that I ride almost daily. I need to upgrade the luggage make it more practical. I ride the absolute shit outta mine, off-road and on road. It’s only got 25k on it but I’ll ride this thing till it’s cobbled together basket case, then buy a new one.
They’re proven reliable, Wattman (the guy who invented the thermobob) has around 180k on his original engine, lots of KLRs have done over 100k, so it sounds like you have a lot of riding to do before then!
Thanks! I used Rustoleum for plastic on the plastics and Rustoleum professional paint and primer on the frame and crash bars. Everything is holding up well even 2 years later through mud, rain and salt.
Love the video really appreciate you actually naming all the parts because you've built a pretty sweet bike there; one question.. do the rental banshee bars come filled with silicone or did you fill them? They look awesome and I want to make sure I buy the right thing if I get them
Thanks! These particular Banshee bars came filled with silicone, but they are older models… but good news, a tube a silicone is about $6 at Home Depot! 👍🏻
@@joeyk810gotcha, I love my gen 1 but the handlebar vibes are a bit much so I'm definitely on the hunt for a new set of bars to bring them up a hair for standing and hopefully chilling out some of the vibration
Next level video - thanks! So did they offer white or did you or another address a repaint clean look Great walk around : spec details Awd it the next update !
Thanks I’m hoping to upload some off road riding clips soon! I painted the frame and tank with Professional Rustolium paint and primer in a rattle can, it’s holding up well!
This is an awesome set up thanks for the video and ideas Im wanting to purchase a 2003 KLR 650 and this is a great rig! What is your experience with MPG's on this bike ill be using this for highway commuting to work ill be doing mainly 110-120kmph 70-75 MPH
I’m getting exactly 50 MPG on low grade pump gas! I get nearly 300 miles range with the stock tank. It will cruise 70-75 MPH all day with no problem, I am running stock gearing but you might want to switch to a 16 tooth front sprocket if you ride mostly highway. I stay mostly on 55mph roads or less, I use it mainly for riding around town running errands and recreational riding.
I had a gen1, forget the year but was red and black. I put a Corbin seat and progressive springs in the forks.. was ok.. for me though, it did everything but it sucked at it.. it was an only bike at the time. it was a crappy road bike and a crappy off road/fire road/trail bike. Living in Phoenix it a ways to the trails which can be rough and long.., maybe in a more rural area it would be more useful.. went back to a XR650L, still a crappy road bike but Rocks off the asphalt. have a Vstrom for the tour related rides.. don't miss the KLR at all.. sorry.. just my experience...ymmv..
The way I have this KLR set up it is an ideal road bike for more, which is basically all I use it for, in Michigan where I live there is a lot of pot holed and gravel roads and this bike excels on that, plus is a super nice cruiser on smooth roads. I had an XR650L for 2 years and although it was a okay dirt bike, it still wasn’t even close to my yz450f off road. The XR650L wasn’t good on the streets, vibrated a lot, wasn’t smooth going through the gears and it was super uncomfortable for long stints of street riding and wasn’t good for carrying any luggage. I liked the XR650L a lot as a dual sport bike, but purely as a dirt bike it was too heavy and purely as a street bike it was plain not good. The KLR is a much better street bike, it is way smoother, more comfortable to ride and can hold a lot of luggage and gas, and it’s still capable to ride off road. But like I said, when I do ride off road I just take my YZ450F if I really want to get technical… although the trails I take my yz450f on, I could still do on the KLR, just not as easily or quickly. All that being said if I could only keep one bike it would be the KLR because it’s the best bike to do everything that I would like a bike to do when and where I would like to do it.
Great video and nice build. I love the straight white. Nice and understated. I've had good luck with my progressive springs up front and finally bought the progressive shock. I was humming and hawing over the Cogent, but it was going to be a lot to get it to Canada, so progressive it was. How's the oil burning with the 685 kit?
Thanks! If I didn’t already have this progressive shock laying in the garage I’d probably give the cogent a try, but for the riding I do on the KLR, the progressive shock works very well, I have a yz450f for riding supercross lol. And the 685 kit is ideal, I’ve put nearly 3000 miles on it since the install, hasn’t lost a drop of oil.
, Where are you at in Michigan? I have an 1988 that I bought new. It only has a bit over 10K on it, but I have loved it. I love to see what it could become.
Just read your comment. My KLR was stolen and I just recovered it. Unfortunately they parted it all out. I do need new fenders and will definitely be getting several things from you guys
I would try to keep it under 30k miles, but wouldn’t be afraid to buy a clean and nice bike with up to 50k miles. Most KLRs don’t get ridden enough to the point of engine failure, many of them get parked with strong engines. I’ve seen many KLR engines go over 100k miles when properly maintained; they are one of the most robust thumpers ever manufactured.
@@k_sey.9370 there will frequently be KLRs popping up for sale, I recommend holding out for a bike that you are sure you really like, even if it costs a little more is or is a further drive to pick it up.
That was only on the early models up until 96, the XR650L uses that style locking mechanism and it wears out the countershaft splines on those. 96 and newer KLRs have the modern style and they work reliably.
@@joeyk810 mine is a 95 9000 miles many new parts , but the transmission puntput shaft barely holds a new sprocket , it appears to me the shaft was not heat treated properly , the splines should not be worn already , it should be harder than the sprocket , mine had the original sprockets when I bought it , any idea on how to repair those splines ?
@@richardmorrison2686 some folks run afterward wider sprockets, some folks have welded and ground down the splines to work, I personally would split the cases and instal the 96 and newer style or find a newer replacement engine if the splines are shot.
Hey slick Rick, I didn’t specify because I built this bike out of 4 bikes ranging from 1987-2007… but that doesn’t matter because all first generation KLR parts are interchangeable.
I just bought a 2004 today that is beat to heck.
I love everything you’ve done to yours, and would love to get a parts list!
I am 47 and this is my first bike, and I don’t even know where to begin… Lol
my uncle just uncovered an old 2004 cosmetically beat up klr with 7000 km on the clock. its a gem i love it. its going to be so much work but so worth it. its pink because of the plastics ahahaha
Bought a 2005 this morning, the previous owner left all his accessories on the bike, wider footpegs, spot lights, crash bars, higher windscreen, 2008 front fender conversion, basically I'm pumped, can't wait, sold my dl650 v-strom a couple of months ago, it was a very good bike, but I'm more a carburetor guy, not much can go wrong with the KLR
The DL650s are nice bikes but the KLR is where it’s at for simplicity and capability
Kudos the cup holder!
This looks so CLEAN
Holy man
Thanks!
This thing is CLEAN! Thanks for the great info
Lovely bike, would love to see how she runs, on and off road!
Hopefully soon I will get some footage!
The stock brakes were a problem for me as my other bike was a baby ninja with sintered brake pads. I waa off of for almost two month and on the KLR as my daily commute until I got caught up on maintenaince. I started of to work with a cold high idle, and a freshly sealed parking lot covered with dew. I grabbed a KLR handful of brake and was on my arse in a heartbeat.
I also had reversed my baby ninja
Awesome bike :) just picked up a 2004 for a bargain and cant wait to start to make it my own :) its in the shop atm getting a roadworthy and im so pumped to get it home so i can start riding it, iv been trying to decide what color to paint it as the plastics are looking its age and i must say White looks mint :) its been 1 year since you done this video! still happy with the bike ?
Nice! Ya the bikes been awesome, basically the same since this video but I did swap out the Progressive rear shock and went with a Cogent shock which I like a lot.
You've done a lot of mods. I've go the progressive springs and race-tech emulators, but not put them in yet. I really like those crash bars. You're ready to go to the ends of the Earth. Let me know when you leave and I'll ride with you :)
Just picked up a gen 1, looking forward to making it "my own".
Great bikes, best wishes with it.
@@joeyk810 How did you get all the plastics painted?
@@illyadmark3223 rustoleum premium paint for metals and plastics in a rattle can. Gotta clean and scuff the plastics thoroughly before painting so the paint won’t flake off over time.
Beautiful job man.
Makes me want to trade my vstrom for one even more!
Thanks! V-stroms are great bikes but the KLR checks all the boxes for me ✊🏻🏍️💨
@@joeyk810 Yeah feel ya..it makes sense, 330 miles of go, it's lighter, plus grunt proof tough.
I'm convinced.
@@12lionwhelps71 it’s simple, cheap, reliable and capable, excels at nothing but is sufficient at everything. And personally I find it to be one of the most comfortable and best handling bikes when set up correctly. I try to avoid the highway and chaotic traffic so I stay on 55mph and under roads most of the time even it takes a little longer and for that type of riding, mixed with Michigan potholes and rutted out gravel roads, the KLR is king.
Cool build. I got a 2018 that I ride almost daily. I need to upgrade the luggage make it more practical. I ride the absolute shit outta mine, off-road and on road. It’s only got 25k on it but I’ll ride this thing till it’s cobbled together basket case, then buy a new one.
They’re proven reliable, Wattman (the guy who invented the thermobob) has around 180k on his original engine, lots of KLRs have done over 100k, so it sounds like you have a lot of riding to do before then!
Real nice setup and good looking bike.
Thanks!
Lovely built, I had the 2008 gen2
Thanks!
Love it i made mine white aswell awhile back
One of the best looking klrs I've seen. Did you paint everything white? If so, what products did you use? Thanks
Thanks! I used Rustoleum for plastic on the plastics and Rustoleum professional paint and primer on the frame and crash bars. Everything is holding up well even 2 years later through mud, rain and salt.
Love the video really appreciate you actually naming all the parts because you've built a pretty sweet bike there; one question.. do the rental banshee bars come filled with silicone or did you fill them? They look awesome and I want to make sure I buy the right thing if I get them
Thanks! These particular Banshee bars came filled with silicone, but they are older models… but good news, a tube a silicone is about $6 at Home Depot! 👍🏻
@@joeyk810gotcha, I love my gen 1 but the handlebar vibes are a bit much so I'm definitely on the hunt for a new set of bars to bring them up a hair for standing and hopefully chilling out some of the vibration
@@chrisspain6780 I recommend inspecting the doohickey if you’re getting excessive vibration
One of the best looking klrs I've seen. Is the factory color white or did you pain everything. If you painted it, what did you use?
Very nice upgrades.
Thanks!
Beautiful ride man
Thanks!
Next level video - thanks!
So did they offer white or did you or another address a repaint clean look
Great walk around : spec details
Awd it the next update !
Thanks I’m hoping to upload some off road riding clips soon! I painted the frame and tank with Professional Rustolium paint and primer in a rattle can, it’s holding up well!
Great job sir!
Very tasteful mods, well done!! Adventure Ready! 🏕 🤟
Man that thing runs good! Do you think the jet and air box mod alone would smooth things out a bit?
Yes good jetting and air flow will help. I like the KLX needle.
@@joeyk810 thank you sir! Great video!
This is an awesome set up thanks for the video and ideas Im wanting to purchase a 2003 KLR 650 and this is a great rig! What is your experience with MPG's on this bike ill be using this for highway commuting to work ill be doing mainly 110-120kmph 70-75 MPH
I’m getting exactly 50 MPG on low grade pump gas! I get nearly 300 miles range with the stock tank. It will cruise 70-75 MPH all day with no problem, I am running stock gearing but you might want to switch to a 16 tooth front sprocket if you ride mostly highway. I stay mostly on 55mph roads or less, I use it mainly for riding around town running errands and recreational riding.
@@joeyk810 yes thats great mpg and i will do a sprocket change after i get to know the bike and to the Doo!
I haven't finished the video yet, but did you get the Meyer plastics kit?
wheres a good place to ride in michigan? im in mt. clemons area, but have ridden in grayling area
I had a gen1, forget the year but was red and black. I put a Corbin seat and progressive springs in the forks.. was ok.. for me though, it did everything but it sucked at it.. it was an only bike at the time. it was a crappy road bike and a crappy off road/fire road/trail bike. Living in Phoenix it a ways to the trails which can be rough and long.., maybe in a more rural area it would be more useful.. went back to a XR650L, still a crappy road bike but Rocks off the asphalt. have a Vstrom for the tour related rides.. don't miss the KLR at all.. sorry.. just my experience...ymmv..
The way I have this KLR set up it is an ideal road bike for more, which is basically all I use it for, in Michigan where I live there is a lot of pot holed and gravel roads and this bike excels on that, plus is a super nice cruiser on smooth roads. I had an XR650L for 2 years and although it was a okay dirt bike, it still wasn’t even close to my yz450f off road. The XR650L wasn’t good on the streets, vibrated a lot, wasn’t smooth going through the gears and it was super uncomfortable for long stints of street riding and wasn’t good for carrying any luggage. I liked the XR650L a lot as a dual sport bike, but purely as a dirt bike it was too heavy and purely as a street bike it was plain not good. The KLR is a much better street bike, it is way smoother, more comfortable to ride and can hold a lot of luggage and gas, and it’s still capable to ride off road. But like I said, when I do ride off road I just take my YZ450F if I really want to get technical… although the trails I take my yz450f on, I could still do on the KLR, just not as easily or quickly. All that being said if I could only keep one bike it would be the KLR because it’s the best bike to do everything that I would like a bike to do when and where I would like to do it.
Really like those crash bars. Follows the contours of the bike really well even without the fairings.
Where in mich?
Fenton area
@@joeyk810 not far at all. Let me know if you're ready to trade for a very nice 04 KLR250 ! (I'm not using mine off road as much as I expected)
@@tstonge4982 HAHA! That’s a firm no buddy.
Nice klr build.
Thanks!
Great video and nice build. I love the straight white. Nice and understated. I've had good luck with my progressive springs up front and finally bought the progressive shock. I was humming and hawing over the Cogent, but it was going to be a lot to get it to Canada, so progressive it was. How's the oil burning with the 685 kit?
Thanks! If I didn’t already have this progressive shock laying in the garage I’d probably give the cogent a try, but for the riding I do on the KLR, the progressive shock works very well, I have a yz450f for riding supercross lol. And the 685 kit is ideal, I’ve put nearly 3000 miles on it since the install, hasn’t lost a drop of oil.
I wondered where the front fender on mine came from😂.
,
Where are you at in Michigan? I have an 1988 that I bought new. It only has a bit over 10K on it, but I have loved it. I love to see what it could become.
I’m in the outskirts of south west Flint, I do any work/maintenance on KLR650s and many other models.
Nice bike man
Thanks!
Very cool sir!
Thanks!
One of our Dakar Fairing kits would take this sweet build to another level. Check us out!
Just read your comment. My KLR was stolen and I just recovered it. Unfortunately they parted it all out. I do need new fenders and will definitely be getting several things from you guys
Where can I find the same piston? Nice build!
eaglemike.com
Ever do any 1k + mile trips on her?
$65 for a tyer not here in Australia 🤣
Hi brother, how are you? Do you have side back racks? Because I also thinking to don't buy it! Only the bags!!!
Yes I have pannier racks and I recommend installing them if you plan on running more than a few pounds of weight in your saddlebags.
@@joeyk810 ok 👍
@joeyk810 I understand! I hear like if you have a side bags with out rack, can be burned by the exhaust
@joeyk810 any way, your wheels are amazing!
@@werneralexandercastilloago123 thanks, yes it can burn from the exhaust. Giant Loop makes side bags that don’t require pannier racks.
Shopping for my first bike. I think my mind is made up on the KLR. Would love to find a gen1. How many miles is too many miles for a used gen1??
I would try to keep it under 30k miles, but wouldn’t be afraid to buy a clean and nice bike with up to 50k miles. Most KLRs don’t get ridden enough to the point of engine failure, many of them get parked with strong engines. I’ve seen many KLR engines go over 100k miles when properly maintained; they are one of the most robust thumpers ever manufactured.
@@joeyk810 I have a local gen2 with 50k miles. Price dropped to $2700 & has some accessories. But I might hold off for a gen1 with lower miles.
@@k_sey.9370 there will frequently be KLRs popping up for sale, I recommend holding out for a bike that you are sure you really like, even if it costs a little more is or is a further drive to pick it up.
That is very reassuring. Thank you for that. I don’t have any friends that ride so I’m kinda flying solo on this. Thank you for the advice.
how good on motocross track
Good job. How much do you think $ into all these mods? Jw
Probably between 2000-2500 retail in aftermarket parts
@@joeyk810 shit that's nothing in retrospect. Beautiful bike. Currently looking for one myself.
@@nicholasbaker2904 thanks, the extras that I added are more my personal preferences but not necessary, there’s nothing wrong with a stock KLR either
Someone should cover the poor designed front sprocket locking mechanism, as the front sprocket get very loose on the splines
That was only on the early models up until 96, the XR650L uses that style locking mechanism and it wears out the countershaft splines on those. 96 and newer KLRs have the modern style and they work reliably.
@@joeyk810 mine is a 95 9000 miles many new parts , but the transmission puntput shaft barely holds a new sprocket , it appears to me the shaft was not heat treated properly , the splines should not be worn already , it should be harder than the sprocket , mine had the original sprockets when I bought it , any idea on how to repair those splines ?
@@richardmorrison2686 some folks run afterward wider sprockets, some folks have welded and ground down the splines to work, I personally would split the cases and instal the 96 and newer style or find a newer replacement engine if the splines are shot.
No good you have to spend 1000s to make it a better bike me I'm going to just go get one redy ro hope on and go I'm a millonare😂
What the fuck year is it, how is that not the first thing you say/type
Hey slick Rick, I didn’t specify because I built this bike out of 4 bikes ranging from 1987-2007… but that doesn’t matter because all first generation KLR parts are interchangeable.
You lost me at “Maybe you’ll learn something”
That’s an effective attitude to remain ignorant.