An essential mod for pre-O8 KLRs is to upgrade the subframe bolts. Those bolts have failed many, many times on KLR overland excursions, with bad results.
I seem to recall reading that the O8 and later models shipped with stronger bolts, but check that. I've been out of the KLR scene for a while (in favor of the DR.  )
Dual-Star sells a subframe upgrade kit. I installed it on my KLR back in 04, no sweat. Well, OK, a little sweat. There are other options as well. Much more info at klr650.net. Good luck.
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