This is a partial list of things I updated or replaced to get the bike prepared for such an adventure. Many of the things below you would do to prepare any motorcycle. Some of the items are specific to the KLR

Suspension. Since we will be riding two up, I upgraded to Progressive springs in both the front forks and rear shock.

Seat. Most stock seats simply are not up for such distances. I replaced ours with a 2007 Afrika Single Seat. I'll let you know how it measures up.

Tires, chain sprocket. I did not have a chance to test any tires with the KLR other than the original Dunlops. Since they didn’t last long I decided to go with something else. I chose the Avon Distanzias for the front and rear with the upgraded radial for the rear. We'll see if they live up to Avon's claim of superior stability, grip and distance. I fully expect to have to replace the tires at least once during this trip. I will likely be at the mercy of whatever is available when it comes time to replace them in South America. As for chain and sprockets, that was a no brainer. I started with a new Regina o-ring chain. Experience has taught me that this chain will likely go the distance and then some so I don’t plan to carry an extra. I also started with fresh steel sprockets front and rear and also expect them to go the distance. I added one tooth to the rear given the extra load the bike will be handling and the type of roads and elevations we will be riding.

Handlebars. I like a good strong handlebar so I replaced the stock ones with Pro Taper CR High bars. I added a set of quality hand guards and reflectors.

Safety. Given the weak performance of the stock front brake, I plan to add an oversized rotor and steel brake lines. I added a fort brace to the smallish 39MM fort tubes. I replaced the brake light with a much brighter, lower current LED brake light system.

Centerstand from Dual Star - very nice!

Panniers from Happy Trails

Rear trunk with back rest from Givi.

Alarm system

Cover

Dohickey – fix known failure point on KLR’s

Rear brake pedal bracket – failure point on some KLR’s

Riding Gear
I will be using my two year old Roadcrafter from Aerostitch. Clara will be testing the new Olympia line of riding gear. We'll be using tried and tested riding boots. We will also be trying the new Nolan 102 N-com helmets with an integral bluetooth (wireless) intercom system if they become available in time. - Update - the helmets have come in and so far we are very pleased with the quality and comfort. Unfortunately, the bluetooth intercom sets were not yet available by the time we departed. Hopefully they will become availble soon and we can put them to a real field test.