Tim sez: On a ride in the early 90's there was a retired Idaho Forest Service employee, Lew, who was a little "green" on how to pack his KLR. His rear rack bolts fatigued and a field fix was made. The local Boise dealer principle, Carl Struthers, and his mechanic Malone, who were also on this ride took offense that a trip should be inconvenienced by such an issue. The fix was set at the dealer and mandated that every KLR they sold forthwith would have the "healer." The Problem
: The problem concerns the center bolt mounts which help hold the stock A model KLR650 tail rack in place. The factory design has a pressed insert in the rear sub-frame (incidentally, the design allows the bolts to corrode). If a bolt is replaced and it is not the exact length (too long) it bottoms out in the tube and strips the threads. Our fix (the healer
) drills through the subframe and replaces the stock design with a through bolt and nylock nut (to be installed on the bottom side of the tube).
The Fix: A simple 10 minute fix at home can prevent a nightmare on the trail. If these bolts strip or break on a trip, the rear tail rack loses it's stability. 1-2-3 and done ... if all of life's problems could be remedied so easily!
Quick fix for a known factory tail rack issue on the KLR650A (1987-2007)
Uses stainless steel bolts to prevent rusting
Necessary drill bit included in kit
Included: Bolt Kit, drill bit, and instructions
All Happy Trails products are crafted in Boise, Idaho