Charon wrote on 07/17/08 at 20:17:42:I had a KLR 650, an '06. The KLR is considerably more powerful than the Savage, as it is oversquare bore and higher compression. It is also water-cooled and revs higher. The KLR is probably 10-15 mph faster. Fuel mileage is similar at similar speeds, but the KLR has that lovely 6.1 gallon tank. I found the seat on the S40 (mine is an '07) less uncomfortable, but the suspension on the S40 is worse. The KLR is said to be underbraked (so is the S40), but I didn't have problems. I like the seating position on the KLR better. The reason I traded off the KLR was its height. I couldn't flat-foot it, and I never felt comfortable "paddling" it around with my feet. It made me very nervous on rough ground, because I always was afraid I would lose my footing and drop it. The mirrors are much worse for vibrating on the KLR. The KLR comes equipped with a nice rear luggage rack, and has a disk rear brake and chain drive instead of the S40 belt drive and drum brake. The S40 has screw and locknut valve adjusters, while the KLR is shim under bucket, requiring the cams to be removed to make adjustments. The KLR has a trip odometer and a tach, things the S40 lacks. The KLR also costs considerably more.
I also own a KLR, a 2007 model. Charon gives a very good quickie comparison of the two bikes.
The KLR is quite a bit more bike, as it should be (about $1000 more expensive). It handles highway speeds much better than does the Savage, and I find it more comfortable.
The main reason I keep my Savage is that it makes a better errand-runner and town bike than does the KLR. If I want to ride two miles to get a movie, I jump on the Savage. The KLR is water-cooled and takes longer to warm up. I can do short trips on the air-cooled Savage and not worry that I'm harming the engine in any way with incomplete warm-ups.
I also believe the Savage is easier to work on, although I've not yet done much work on the KLR.
Build quality is similar on both bikes (i.e. on the cheap side).
The KLR, obviously, is MUCH more versatile. I'm currently modding mine for ATW-type travel.