"When working on a motorcycle, you will invariably get stuck. When this happens, take a break and remove yourself from the situation. Drink approximately 6-12 beers. The problem will remain, but you will no longer care." - MM: Zen and the Art of Drunken Motorcycle Maintenance
If, due to Google's organic search results, you arrived here with the intent of replacing the head light bulbs of your KLR650, I implore you to reconsider. It is simply not worth it. Take my advice and just sell the thing. It will save you a really big headache.
Accessing the headlight of a KLR 650 is more difficult than teasing an orgasm out of a eunuch. The Clymer manual reads like the blueprint of a Rube Goldberg machine. Direct quote from the manual:
1) Headlight Inspection/Replacement: To access the headlight, remove the front fairing.
2) Front Fairing: To access the front fairing, remove the rear fairing.
3) Rear Fairing: Unscrew anything you can see, put the screws in a little pile, unscrew anything exposed by the first round of unscrewing, and repeat a few times until the motorcycle is sitting in a pile on the ground.
4) Root around the pile and find the light bulbs, throw the old light bulbs away, reassemble by reversing steps 3 to 1.
It took my hours to replace the headlight bulb, WITH help and WITHOUT beer. I considered duct taping a flashlight to the windshield or just, like, wearing a miner's helmet at night. I considered becoming a mechanical engineer and revisiting the headlight problem after getting my degree.
I did my best to follow the Clymer instructions. I removed the fairings, which included hex bolts. I do not understand the logic of randomly intermixing regular bolts with hex bolts. (Is "hex bolt" even a word?) Once the fairings were off, the lights are inconveniently housed in some sort of device that required more unscrewing. As I was, at long last, removing the actual headlights, it dawned on me that I shouldn't be mashing them into the cement floor, but only after scratching the hell out of them.
By the time I replaced the light bulbs, there was something like 500 screws scattered throughout my designated parking space. I had my doubts I would ever get it back together again, and even if I did, I just sort of expected the whole bike to fall apart the next time I rode it.
Once I reattached everything, I turned the key and smiled when I saw the headlights shine against the wall of the garage. I walked to the front of the motorcycle to inspect my handiwork. Only one of the two headlights I replaced was working.
I sat down and cried.
I sat down and cried.