This is basically a copy of post I put on Advrider. But I also got lots of info from the Hubb so I wanted to feed back my findings here too as it might be of use to other people.
I spent a bit of time getting my KLR set up for a tour to Morocco:
"Tick the box" Ireland to Moroccon tour on a KLR650 - ADVrider
The following are the few bits and pices that I did to the bike.
GPS (Garmin Zumo) Installation
The main advice for hard-wiring the GPS to the KLR was to use the two spare wires near the head-light. As mine is the European model, these are used for some kind of City Parking light. On the bottom right of the head light assembly.
The whole light bulb can be pulled out so I dicided to splice into these wires. I was nervious of cutting the wires so I used scotch connectors which clip onto two wires splicing then together.
This was a bit of a disaster because the gague of the GPS wire was too small and made a bac connection. After a bit of messing around I got a good connection and it has worked fine since:
Power Output for Phone, Ipod, Electric Pump
I decided to use an SAE type connector as an external power supply. It is nice and neat and doesnt require drilling of any body work. I wired it directly to the battery and it hangs out just under the frame where the tank meets the seat. It is nothing fancy but does what I want it to.
IMS Foot Pegs
Very happy with these, nice and wide for a bit more comfort and a noticable improvement in control in the wet.
IMS 6.6 Gallon Fuel Tank
The tank on the standard KLR 650 Cmodel is only 14 liters. Some sites say the IMS tank will not fit the Cmodel. However if you make a bracket to move the mounting point on the seat, it fits ok. THe end result is the end of the seat does not fit snugly on the tank but I can live with that.
In the end I got a tank bag with a seperate base and the base is left on the bike. It pulls the seat onto the tank perfectly so I have no worries about water getting in.
Finally I added soft ortliebe throw over panniers as discussed in this thread:
I was very satisified with these panniers.
I had a simple heavy duty gear back which I had from an old job for carrying safety boots and gear. This was perfect for a tent, small sleeping bag and mat and some tools. This was fine on the road but off-road the setup moved around too much. Also once strapped down it was impossible to access the contents.
I had a very nice Giant Loop Fandango Tankbag
. This was a lovely bit of kit, a perfect size for me, room for a camera, book and a few little bits and pieces and with a map pocket. The whole lot zips off a base which is handy at night and for petrol stops. I generally dont like tank bags but this was very unobtrusive, except for maybe on steep hill climbs.
I got the tank bag from Adventure Spec, who gave great customer service. They had loaned their last tank bag in stock to TBM magazine for a photo shoot but aranged to have it picked up from the TBM offices and sent on to me. Because of the day or two delay they even included a free heavy duty tube and repair kit. Highly reccomend these guys:
Adventure-Spec Shop Home Page - adventure-spec.com: Off-Road Adventure Motorcycling gear,UK,enduro,rally,rallye,touring,rtw,mx
I was parinoid about puncturers so I splashed out on the Cycle Pump and bead breaker. They were efficiently delivered from metal muel. THe pump is a lovely bit of kit, very small but quite sturdy.
THe bead breaker is a bit on the heavy side but I was worried about being on my own and not being able to break the bead. It works very well and although I didnt have to use it in anger on the trip, I was glad I had it.
I used a bar from an old dumbell as a prop and it was perfect for lifting both the front and rear end of the bike for tire changes and chain lubing.