08 KLR Falling apart.

[bigchief]

I got a 2008 KLR 650 on May 27th (My 25th wedding anniversary). Have 520 miles so far but now wondering what else will fall off before the 600 mile service. Five days after I got it, the right front turn signal rubber boot broke and the light was hanging only by the wire. The bike had not been dropped or ridden off-road. Tuesday I took it back to the dealer and they were not aware of any problems with this but said one would be ordered. Wednesday, rode to work and when I returned home the LEFT REAR had done the same. Back to the dealer I go. Ordered that one also. Was told this would be under warrenty. Has anyone else had or heard of this problem?

[SilverEagle]

Depends if someone didn't bump into something with it during assembly before it was handed to you? A Coworker of mine has one, and he has had no problems so far?

[KLR_Pilot]

At about the 1500 mile mark both my rear turn signal rubber stalks failed at the frame mount . . . with in about 10 miles of each other. I was out on the trail and had to duck tape/zip tie the signals in place. The dealer (Sunrise Cycle in Norfolk, Virginia) replaced both with out any problems. At about the 2K mile mark, my tail light failed . . . one of Virginia's finest pointed that out for me. I noticed earlier in the day that it was out, but I didn't have a spare bulb and I was already running late for work. At 2:00 o'clock in the morning, on the way home from work, I was racing a buddy of mine on his BMW down an on ramp when the Statie pulled me over. He said he clocked my at 87mph, but wasn't going to give me a ticket for speeding (I was in my Desert Cammie uniform), but he kicked me off the Interstate because my tail light was out. At about the 2.2K mile mark my low beam failed.

I now have about 12K miles on my '08 KLR (not bad for 10 months of riding) and I have had no other problems/complaints about the bike. Well, one gripe, I replaced the stock windscreen with the 4" taller screen and the windshield mounting screws are crap. The rubber grommets were all dry-rotted and cracked . . . a good design, but poor execution.

[bigchief]

Checked on KLR650.net and found that many people are having this problem. The new stalks have a different part # so mabye the part is better. Also, thanks for the info on the taller screen. I've been thinking about one.

[KLR_Pilot]

The taller windscreen unloads quick abit of buffeting from my chest. Now the buffeting catches just at the top of my helmet, if I tip my head forward just tad, the wind goes up and over. I guess I didn't realize how much wind I was catching until I swapped out the wind screens. I still get full right/left freedom of movement and it doesn't look as 'dorky' as some of the photos I've seen. My brother put a Laminar Lip on the stock wind screen on his '08. They both seem to shed about the same amount of air. The 'Lip looks a little cooler, though. Both are quality products.

[Inquisitive]

I just got back from a 2,333.2 mile round trip ride from Seattle, WA to Anaheim, CA. I rode straight through (except for gasoline stops, about eighteen hours down, and nineteen hours back. It made for one sore back side!!! I had no troubles with the bike, except one "detail" with an accessory I had installed by a technician (won't go into that, except that I fixed the problem while on the road - electrical). I usually get 45mpg to 50mpg around Seattle. With seventy pounds of predominantly tools, and road trip service supplies, myself 220#s, and my Aerostich I only averaged about 35mpg each way. Though admittedly I was exceeding the posted speed limit at every opportunity. I never went over 110mph though went 110mph only briefly once on the way down, however I suspect my average speed in CA was about 90mph (all according to my speedometer). My bike is an all stock 2008 KLR and I started the trip with 3729.3 miles and a full tank of "premium" and returned with a effectively worn out rear tire and 6062.5 miles, burning "premium" all the way. One negative I did not mention above is my bike drank 3.5 quarts of motor oil round trip! None leaked out. I was down one full quart at Red Bluff, CA when I looked at the sight glass. I added one quart of 10W40, I ultimately added two more quarts of 20W50 while in CA, and added a 1/2 quart of 10W40 (as heavy weight as the store had) in Centralia, WA. Since I am back to not "consuming" any oil at all. I suspect such consumption was do to "high speed" travel for long extended periods of time. I effectively always traveled "ten over" according to my speedometer, however anytime a "cruiser" passed by me, I hopped right on their tail and stayed with them till they or I exited. Once "we" traveled for an hour at 100mph. "Speeding" was never a problem, except near Gorman, CA where my top speed was only 65mph full throttle into a very strong head / cross wind, also at about 4,000ft elevation. The cross winds on the way back were quite "attention getting". Often leaning into the cross winds as much as I would into any high speed highway turn. My cargo was in two milk crates (large size, rectangular - 6 gallon) stacked on top of each other, mounted cross wise on the Kawasaki 22# rated cargo rack. Sitting upright on the bike, my body effectively completely shadowed the crates from on coming wind resistance. The best mileage I ever got was 44.9 on the last stretch home, and the worst mileage was 30.5 between Red Bluff, CA and Thornton, CA the stretch where I went the fastest the longest (I suspect). I only lubed my chain once on the way down in Red Bluff, CA, again when I arrived in Anaheim, and twice on the way back, in Woodland, CA, and Cottage Grove, OR. Some information for you.

[fretbuzz]

I too have heard of others that have had similar problems with the new KLR. In my opinion the previous version at least looked better.

[bigchief]

Good trip Inquisitive. Haven't ridden mine that hard yet. My long trips are still my Nomads job but I will be riding my KLR to Deals Gap. Been there several times but I can't wait to try the Dragon on the KLR.
No other lights have fallen off and I see no oil usage yet.

[Inquisitive]

Big Chief, if you have not already, I suggest you add a throttle lock to your KLR. I adapted one, and it worked great! Curious thing, when I ride my KLR (loaded up for a trip or not) my KLR rides effectively perfectly up right. When I let go of the grips and use the throttle lock, I have to lean quite a ways over to the right side of the bike to keep it balanced. As soon as I grab the grips, I no longer have to lean over to keep the bike balanced, go figure? I mounted, and had a technician actually wire in a 12 volt accessory receptacle so I could charge my cell phone while on the trip. Unfortunately the tech did not secure the positive lug on my battery well and ultimately caused me several hours of effort to correct the "installation", in a manner I was satisfied with, as I suspect I am far more particular than the technician who did not notice the poor battery terminal connection. Unfortunately the battery (new with the bike) has very short terminal bolts, not leaving room to add accessory wire "eyes" below the terminal bolt (need a longer bolt), though the battery construction does not allow for much more than about a one millimeter or so longer terminal bolt. I found I did not need "highway pegs", however a more comfortable seat would have been nice. I do not recommend riding eighteen plus hours straight on a KLR only stopping for gas and chain lubrication. My trip was more or less out of financial practical necessity, though somewhat fun just the same. A 2008 KLR is more than capable to cruise down any highway, even for an extended distance / period of time, however a KLR is not a long distance highway cruiser. I suspect most all KLR owners know such. Best of luck to you!

[tupelo77]

Originally Posted by bigchief

I got a 2008 KLR 650 on May 27th (My 25th wedding anniversary). Have 520 miles so far but now wondering what else will fall off before the 600 mile service. Five days after I got it, the right front turn signal rubber boot broke and the light was hanging only by the wire. The bike had not been dropped or ridden off-road. Tuesday I took it back to the dealer and they were not aware of any problems with this but said one would be ordered. Wednesday, rode to work and when I returned home the LEFT REAR had done the same. Back to the dealer I go. Ordered that one also. Was told this would be under warrenty. Has anyone else had or heard of this problem?

Same problem today; found my right signal dangling. I have a Pelican Case protecting the signal so could not have hit anything. I'll see the dealer this weekend. Hopefully, they will take care of it, Dan

[Inquisitive]

Question for you, exactly what portion of your turn signals are "dangling"? I have noticed that two; one front, and one rear of my turn signals seem to be working their way off of the "post" for lack of a better description (the piece between the frame connection and the actual light fixture - the flexible part...). I was able to simply (carefully) wiggle / work the turn signal right back onto the "post". It almost appears to be designed as part of the "break away / safety portion" to help protect the turn signal in the event of a "mishap". Any thoughts? Let me know what you can. Thank you.

[tupelo77]

Originally Posted by Inquisitive

Question for you, exactly what portion of your turn signals are "dangling"? I have noticed that two; one front, and one rear of my turn signals seem to be working their way off of the "post" for lack of a better description (the piece between the frame connection and the actual light fixture - the flexible part...). I was able to simply (carefully) wiggle / work the turn signal right back onto the "post". It almost appears to be designed as part of the "break away / safety portion" to help protect the turn signal in the event of a "mishap". Any thoughts? Let me know what you can. Thank you.

The rubber breaks. At that point of breakage, the rubber has a ragged tear;almost looks like someone twisted the signal intensionally, but that is not the case. The rubber doesn't feel dry-rotted either. The only thing holding the signal in place is the wire. My dealer's service manager had never seen the problem. I gave him the KLR.net link. Well see what happens.

[Inquisitive]

Originally Posted by tupelo77

The rubber breaks. At that point of breakage, the rubber has a ragged tear;almost looks like someone twisted the signal intensionally, but that is not the case. The rubber doesn't feel dry-rotted either. The only thing holding the signal in place is the wire. My dealer's service manager had never seen the problem. I gave him the KLR.net link. Well see what happens.

tupelo77, where exactly is the rubber breaking at? Near the light fixture? Where it attaches to the bike? Can you post a picture? Let us know what you can. Thank you.

[bigchief]

Both of mine were like Tupelo said but mine did appear to be dry rotting. All is well now. Dealer replaced both at no charge. Did have to wait though. They were on BACKORDER. Ha.