Fan or not, most acknowledge the Kawasaki KLR 650 is a versatile machine. From single track to your daily commute or a tour across South America, it will take you just about anywhere you want to go. While it’s known for being a budget bike, many choose the KLR 650 because of its exceptional reliability, durability and simplicity, regardless of price.

It was cutting-edge technology in 1987 when it was first introduced but not much has changed over the last 28 years.

The KLR 650 is not without its flaws though. One of its biggest shortcomings is the suspension. The pre-2014.5 KLR 650s are known for being too soft, even for an average-sized male without luggage. Out on the trail, it does a poor job of absorbing big hits and is quick to bottom out. If you push it too hard or if you are a little heavier than average, the KLR 650 rear shock can begin to fade and even blow seals.

That’s not to say the suspension flaws are so ingrained in the bike’s design that they can’t be fixed. The KLR 650 is relatively light for an Adventure Bike (40 pounds lighter than the BMW F800GS) and at its core, it’s really more dirt bike than street bike. Its compact size, 21″ front wheel and dirt bike ergos give it the perfect blueprint for an off-road capable adventure bike.

There’s a lot of hidden performance in the KLR’s DNA and one of the best ways to bring it out is with a suspension upgrade. But can an upgraded suspension really transform the budget-friendly KLR 650 and put it on par with off-road capable adventure bikes that cost two or three times as much?

Searching for the Best KLR 650 Suspension Upgrade

While reviewing the KLR 650 suspension upgrade options for our test bike, our first priority was maintaining the bike’s reliability and durability. We wanted high-quality suspension components that would handle the constant abuse of long-distance touring and heavy-duty construction to absorb the punishment of spirited trail rides. It would need to be custom-configured to the rider’s weight and riding style and have the flexibility to handle heavy gear and a passenger.

Touratech’s rear shock is built with a 6082-T6 aluminum shock body, low-friction Teflon seals, high-strength stainless steel bushings and an oversized 16mm shaft.

Touratech’s KLR 650 suspension upgrade was a good fit for what we were looking for. We were impressed with their stoutly built rear shock specifically designed to handle the constant abuse of long-distance adventure touring. Its floating piston design eliminates the inconsistent damping that plagues the stock emulsion shock, and Touratech keeps it simple by using a single clicker for both rebound and compression damping. A shock length adjustment allows you to set the ride height (up to 8mm) without affecting shock travel (extremely helpful if you are inseam challenged) and an optional hydraulic preload adjuster can be used to fine tune preload by hand for different load weights.

For the front end, big improvements can be gained by swapping out the old linear-rate fork springs for progressive fork springs. We opted for Touratech’s KLR 650 progressive fork springs kit that gives a supple ride over small bumps while getting progressively stiffer as the forks compress deeper into the suspension travel.

Suspension Test: Timed Off-Road Course

In order to measure the improvement gained from the Touratech KLR 650 suspension upgrade, the bike was put through a technical off-road challenge and lap times were recorded both before and after the installation. To get a true sense of the KLR’s capability, we pitted it against one of the best off-road Adventure Bikes ever built — the KTM 990 Adventure R. The KTM would also act as a benchmark for our before and after tests, allowing us to measure the gap in time between the two bikes on the same date, with the same rider, without varying trail conditions playing a factor.

The KTM rides on a race-bred suspension with significantly more power and suspension travel than the KLR 650. At first glance, this may look like an unfair comparison but the lighter KLR has a fighting chance with its more nimble handling on a technical course.

With 76 more horsepower and 2 extra inches of suspension travel, the KTM 990 Adventure R is a formidable opponent for the KLR 650.

Enter the Arena

The 2.3-mile course was designed to be a true test of suspension function with few sections where the KTM could use its significant power advantage. The course travels down through a set of sandy s-turns before entering a long section of medium-sized whoops. Up a steep rutted-out hill climb, then continues on a ridge trail where the rider navigates through a maze of baby head boulders and ruts. Hard left into a steep v-shaped ravine that can easily bottom the suspension, then watch out for embedded rocks through a roller coaster of ups and downs that includes natural jumps. Pass through a long set of motocross-style whoops before a sweeping right turn marks the furthest point of the course. Head back through the giant whoops, roller coaster section and deep ravine before starting the 3/4 mile climb through long continuous whoops all the way to the finish line. One lap takes a little over 5 minutes to complete.

Our suspension test course featured plenty of big whoops that would allow us to push the KLR 650 suspension to the limit.

Round 1: Stock KLR 650 vs. Stock KTM 990 Adventure R

While we were pretty sure the stock KLR 650 would lose our first challenge, we weren’t sure by how much. Heading out for some hot laps on the KLR 650 was a bit of a shock after riding the refined KTM. The bike danced wildly through the whoops and the stock KLR 650 rear shock bottomed out frequently. We received bone jarring impacts from the front fork and the bike struggled to keep the tires planted on hill climbs.

The KTM 990 Adventure R suspension felt refined and under control in the whoops.

Dropping into the ravine on the KLR required caution to avoid a hard bottoming out of the suspension. Overall, it was a scary and unpleasant ride but we pushed to the limit to achieve our best time.

The stock KLR 650 suspension struggled for traction and had difficulty maintaining a straight line on steep hill climbs.

After recording the best of two runs for each bike, we were not surprised when the KTM 990 Adventure R beat the stock KLR 650 by a gap of 0:23 seconds. That’s a big gap when you consider this was a short course. More importantly, it required a lot more effort and stress to ride the KLR 650 at higher speeds. Nevertheless, the KLR would be back for a rematch after installing the Touratech suspension.

Installing the Touratech Suspension

The rear shock and fork springs upgrade is a fairly simple job for anyone with basic mechanic skills and tools. If you are new to working on motorcycles, we recommend taking it to a shop to ensure the job is completed properly. You can take a look at some YouTube videos for KLR 650 fork spring and rear shock replacements to get a better idea of what’s involved. Set aside a day to complete the job and always read the instructions carefully before beginning the project.

Touratech’s KLR 650 progressive fork spring above and stock spring below.

Touratech’s progressive fork springs kit for the KLR 650 includes springs and fork oil. Taking apart the forks may look intimidating at first but it’s a fairly simple operation and the instructions are straight forward. The forks are removed from the bike to completely drain the oil and the stock metal preload bushings are discarded. Forks are re-installed 10mm higher in the triple clamps to set the correct ride height.

Touratech’s KLR 650 rear shock with hydraulic preload adjuster above and stock shock below.

Replacing the rear shock is even easier than the fork springs. It takes less than 10 minutes to remove the 3 bolts holding in the shock. Bolt the new Touratech shock into place with thread lock and your rear shock upgrade is completed.

The rear shock comes shipped from Touratech with settings optimized for your weight and riding style but you should always double check your “race sag” to ensure it’s adjusted properly. Touratech offers two useful resources that describe best practices for setting suspension sag and fine tuning damping settings on your new shock.

Round 2: KLR 650 With Suspension Mods vs. Stock KTM 990 Adventure R

With our new Touratech suspension installed on the KLR 650, it was time for a rematch with the KTM. Our initial test runs revealed a major transformation in the KLR.

The KLR suspension upgrade smoothed out washboard surfaces, and sharp edged bumps no longer rattled kidneys. Overall, the bike had a plusher more playful feel.

After achieving our best time out of two runs on the KTM 990 Adventure R, it was time for a lap on our upgraded KLR 650. In the whoop sections and hill climbs, the KLR stayed arrow straight. Heading down the ridge, the steering felt much lighter than before, making it easier to navigate the ruts and rocks scattered along the trail. Diving down into the ravine, we were able to carry more speed without bottoming out.

We could feel a big improvement with the KLR 650 suspension upgrade on the first lap, but we knew we could squeeze more out of it with some adjustments. For the second run, we increased damping on the rear shock to improve its ability to handle bigger hits. This allowed the KLR to stay on top of the whoops better.

Increasing the damping adjustment on the rear shock helped the KLR 650 stay on top of the whoops and carry more speed.

We put in our best effort and the damping increase paid off. Our final run dropped the gap to within 0:09 seconds of the KTM 990 Adventure R.

Where Was The KTM 990 Adventure R Faster?
The course was designed to prevent the KTM from using its power advantage but the split times on different sections of the course revealed a few spots where the KTM was using its extra grunt. Whenever there was a steep hill climb on the course, the KTM distanced itself slightly. Its longer-travel suspension also allowed it to achieve higher top speeds through the long whoops section.

The KTM 990 Adventure R gained time on the KLR 650 by using its power advantage to blast up hill climbs.

Where Was The Modified KLR 650 Faster?
Improved steering and maneuverability paid dividends for the KLR on the rocky ridge trail, allowing it to gain valuable seconds on its heavyweight competitor. The KLR was able to pick cleaner lines through the rocks and ruts and could carry more speed through turns than the KTM. The KLR 650 was no match for the big KTM in the whoops with the stock suspension but it was right on its heels after installing the Touratech suspension.

The KLR’s lighter steering allowed it to carry more speed through turns than the KTM.

Final Thoughts

We were left impressed with how well the KLR 650 performed after the suspension upgrade. The Touratech suspension got us within close reach of the KTM (0:09 seconds away) and it was a major improvement over stock (0:14 seconds gained). However, the true value of the improved suspension goes beyond the race course. It’s about how the bike makes you feel when you ride it.

It doesn’t take a racer to tell a difference either. Riders of different skill levels that tested the bike, before and after the upgrades, reported they could ride faster with less fatigue, and that it was easier to react to surprises when they occurred. The bike now feels more connected to the trail and it’s a joy to ride at a brisk pace or just cruising down the road.

The Touratech suspension upgrade transforms the KLR 650 into a more responsive handling bike and improves confidence on rough terrain.

On asphalt, the KLR has a more flickable feel and doesn’t wallow in turns. There’s no excessive dive under braking or squat during acceleration. When riding with heavy luggage or a passenger, there’s plenty of preload adjustment available to set the correct ride height.

A suspension upgrade is one of the best investments you can make in your KLR 650 and there is probably more room for improvement than on any other Adventure Bike. If your plan is to travel significant mileage or you are just looking for outright performance, then the KLR 650 suspension from Touratech is an excellent choice. The high-strength components are built to last and are backed by a 2-year warranty. The rear shock is also completely rebuildable with a maintenance interval of 18,600 miles.

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Photos by Bill Lieras

Author: Rob Dabney

Rob Dabney started a lifelong obsession with motorcycles at the age of 15 when he purchased his first bike – a 1982 Honda MB5. Through his 20’s and 30’s he competed in off-road desert races, including the Baja 250, 500 and 1000. Eventually, his proclivity for exploration led him to dual sport and adventure riding. Rob’s never-ending quest to discover what’s around the next bend has taken him on Adventures in Latin America, Africa, Europe, Asia, and throughout the American West. As a moto journalist, he enjoys inspiring others to seek adventure across horizons both near and far.