Spare Parts for RTW Ride

**liketoride2** · #1 12 Jan 2005

I'm planning a RTW ride for this summer on my 2004 KLR 650 (A model). Would anyone have suggestions as to what major spare parts to take - I'm not asking about things like cables and levers which are a given, but any components that one would especially like to avoid failing in the middle of Siberia, for example. Such as oil pump, water pump, doohickey parts (I already have the Eagle upgrade), etc. Are there any such parts which might be particularly prone to failure on the KLR? I would like to be well prepared, but also not to foolishly take anything which is highly unlikely to be needed, since packing space is at a premium on such a prolonged trip.

Thanks in advance for any advice.

Mike

**davidmc** · #2 12 Jan 2005

I believe the stock subframe bolts are notorious for shearing under heavy loads. There is an upgraded bolt set you can buy to take care of this, but I forget who sells it. I would think the place where you got the doohickey upgrade could help you with this.

Also, I have heard that bypassing the sidestand engine kill switch can be beneficial as it is prone to failure also.

-Dave

**pantrybear** · #3 12 Jan 2005

If you dump the bike there is a potential for the shifter lever to break. There are aftermarket replacements available that you might want to install and then throw the stock one in your bag just in case.

The sidestand switch and clutch lockout switch are somewhat fragile but a knife and some electrical tape will bypass them in a pinch.

Outside of the obvious cables, fuses, tubes, etc. I can't think of anything else offhand.

**liketoride2** · #4 17 Jan 2005

Thanks to both of you for the advice. I much appreciate it.

Mike

**zrod** · #5 27 Jan 2005

Pretty sure you have hooked up with Fred, if you bought Mikes lever.
Those guys are great!
If anyone can give you a shoe in on this topic, they can.
I'd call Fred and give him some time to think on it and see what he comes up with.
He can also supply the spare parts you need.
He's a hellova guy and kicks butt for us KLR Dudes.
Don't forget your water pump parts when you go.
Course I haven't had to do squat to my 03 with 25,000 miles except the idler lever and spring and enricher cable.
Fred will set you up and please keep us posted on your and course our dream cruise!
You Da Mane, cheers!
Rod,,,thinkin you have this link already, but

http://www.arrowheadmotorsports.com/

**liketoride2** · #6 28 Jan 2005

Rod, thanks for the info and encouragement. I have visited the websites of Arrowhead, Happy Trails, Dual Star, Big Cee, Sagebrush, Totally Wired Cycles, Rider Wearhouse, and Whitehorse (have I missed any?) and looked through their lists of parts, gear, etc., and ordered some things. I've also been lurking on the KLR650.net and Adventure Riders forums for the past few months, as well as here on HUBB. The internet is such a fabulous source of info for someone planning a trip like this!

Thanks again.

Mike

[This message has been edited by liketoride2 (edited 28 January 2005).]

**zrod** · #7 29 Jan 2005

Thought your handle sounded familiar!
Good luck and see ya out there someday,
Rod

**DWright** · #8 25 Feb 2005

I just came back from a trip into mexico and all was well, except for the three flat tires. i did drop the bike in Dallas, TX on the left side, which, being quite a bummer, snapped the psuedo metal "C" shaped bracket that holds the clutch lever to the handle bar. That breaking is the epitomy of bummer. Now i carry one extra on every trip....small, light weight and cheap. Also, carry oil filters. Your should be able to find oil but finding the right filters could be difficult. Something(s) to think about.

Quote:

Originally posted by liketoride2:
I'm planning a RTW ride for this summer on my 2004 KLR 650 (A model). Would anyone have suggestions as to what major spare parts to take - I'm not asking about things like cables and levers which are a given, but any components that one would especially like to avoid failing in the middle of Siberia, for example. Such as oil pump, water pump, doohickey parts (I already have the Eagle upgrade), etc. Are there any such parts which might be particularly prone to failure on the KLR? I would like to be well prepared, but also not to foolishly take anything which is highly unlikely to be needed, since packing space is at a premium on such a prolonged trip.

Thanks in advance for any advice.

Mike

[This message has been edited by DWright (edited 25 February 2005).]

**Kurt** · #9 25 Feb 2005

Bummer about your dropping it in Dallas. I've carried extra clutch/brake levers but not the whole assembly. I've been told that leaving the clamping bolts loose enough to allow the clutch lever to rotate a bit in a crash works pretty well. An old dirt bike trick, I guess.

It's hard to say what 'major repair' parts you'd need. The motor is pretty bullet proof. If you do the recommended upgrades I think you'd be OK. That said, I did lug an extra chain around for a whiile but never needed it.

Kurt