I have gone a little crazy here getting set for spring. Spent about $600 for various "farkels" for the KLR. I am happy with them all. I built my own panniers from army surplus Mermite cans, which had been used for carrying food to forward line troops. The cans are good sized and double walled. I had heard rumors of how difficult it was to pry out the inner aluminum skin, but I had no problem using a 90 degree angle grinder with a cut off blade. The toughest part of the whole job was breaking out the foam insulation that filled the space between the double walls. I used a Happy Trail SU rack (built like a tank) to mount the cans and they are solidly attached.
Another upgrade was to replace the highway tires (Dunlop 607's) with a more 50/50 tire. I did my research and decided on Mefo Explorer 99 tires which are like a 60/40 tire. They whine just a little up to about 40-45 MPH and then the rest of the noise from the engine and from wind just drowns it out. I ventured into mud over these last few days, somewhere I would never have gone before, and I made it through...bearly. The tires did the trick but this is no "mudder".
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