The KLR was indeed a beast! I had a 2004 for 10 years, before I got the ST1300.
That bike required very little to no maintenance. I checked the valves once, changed the "doohickey", replaced the spark plug and air filter and used seafoam in the fuel once and awhile.
The "doohickey" was mentioned in the video which made me smile. It's a cam chain tensioner assembly attached to a sprocket. This assembly has be known to break and or the spring attached to it breaks, causing serious internal damage because it maintains chain tension on the cam chain.
These bikes have a bolt head sticking out from the engine at around the gear shifter that is supposed to be loosened, then tightened at every oil change. What this does, is allows the spring to re-tension the cam chain if there is any slack in it. The problem is, you can't tell what's happening inside the engine while you're doing it so if the spring or the assembly is broken, you could be allowing the chain to get even more loose. That's when bad things happen. I read all about it on the KLR650 site. Great informative site, just like this one.
The job was fairly easy but you needed a special puller (nothing someone couldn't make.
) When I reached the tensioner, my spring was indeed broken , but the doohickey was still in one piece. The site said the spring would usually migrate to the other side of the engine and sit behind the clutch basket. That's right where I found it!
Shortly after I replaced the assembly and spring with a more robust aftermarket doohickey, I remember being at the Kawasaki dealership buying some oil and having a new tire installed, when the mechanic wanted to show me a crack in my rim so he brought me downstairs to the shop. One of the other techs was working on a KLR (imagine that) and so I asked him about what they knew about the so called "Doohickey" problems. To my surprise, they knew nothing about that problem, never heard of it they said and they rarely loosen the cam chain tensioner bolt and tighten it. (the manual says to do it)
One of them said "internet myth"
Another reason to stay away from the dealerships!
On a final note, in 10 years I never had to flush the clutch or brake fluid. Imagine that?
Those bikes were used for travelling across the country, in many countries, on many occasions. Very popular.
While the KLR being bulletproof though, and having a huge 26 liter gas tank for the size of the single cylinder bike , I still welcome the St's comfort, power, 29 liter gas tank and very happy with the change!
Long live the KLR!