What size of bike for 2 up ?

Why? It's a reasonable answer. Higher hp available, no meaningful shortening of engine life, it is louder though.
Because it's a horrible idea. If a bike doesn't have the nuts to pull you in top gear what is the point.
 
Because it's a horrible idea. If a bike doesn't have the nuts to pull you in top gear what is the point.
You could make that argument for most bikes. Whack the throttle open in top gear on an average bike and it isn't in a great hurry. Drop two or three gears on the klr and it will give "fast" bikes in top gear a challenge for a few seconds. When the bike is good for 90% of your uses, changing your riding style to improve it for the remaining 10% is cheap and easy.
 
Yes exactly. Any bike that won't haul your *** in top gear needs to be replaced.
The problem is that you could get something like the old Honda V65 Magna or Yamaha VMax, and just leave it in second gear, but they're not meant to carry a passenger, unless you both weigh 150 lbs (68 kg). It's a similar issue with some of the sport touring bikes. I'm not sure if they've addressed it yet, with the more modern versions of cruisers & sport touring bikes.
 
600, 800 ? Or 1100 intruder maybe ?

Why not rent a motorcycle for the day and see what suits the both of you.

Size does matter and the last thing you want is an engine reving so high that it ends up sounding like you are riding a sewing machine.

I would say as a minimum, an 800.
 
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