KLR riders out there

**Woodman** · 20th June 2010, 16:25

Originally Posted by dino3310

either that or you fellas should start smoking more

Then we might start believing that our klrs really are factory prepared mx bikes all the time instead of just occaisionally when we are out riding alone.

**Moki** · 20th June 2010, 20:09

Originally Posted by RedKLR650

...about to do the upgrade

Geez, you southerners take your time. You had that doo off me over a year ago!

Recommend you go with a torsion spring

**RedKLR650** · 20th June 2010, 20:18

Originally Posted by Moki

Geez, you southerners take your time. You had that doo off me over a year ago!

Recommend you go with a torsion spring

Hi Moki,

yep, it's been one of those years, been busy riding the bike rather than farkling...... but due to a police imposed non riding-driving period for the months June/July/August, it's now the perfect time to do all the serious mods

You've obviously done more research on the subject so why do you suggest the trosion spring rather than the regular ones ? Both just as likely to break as the other according to my engineering friends......

Cheers, Stu

**pete376403** · 20th June 2010, 21:23

Just come in from the shed - pulled the alternator cover off and my bike (build date 04/07) is one of the deep hole models. It could be quite nasty if the shaft moves right to the bottom of the hole in the outer cover (and there is nothing to stop it moving, either) - theres nothing left to hold the inner cover side thrust washer in place except the oil film. It could go down and stick to the alternator rotor magnets (if you're lucky) or it could get into the cam or balancer chains (less lucky). After that who knows what shit it could do. Worth checking.
I'm going to bring it up with Motorad and see what the position is with regard to warranty, but I wouldn't hold much hope.

**marks** · 21st June 2010, 08:07

Originally Posted by pete376403

Just come in from the shed - pulled the alternator cover off and my bike (build date 04/07) is one of the deep hole models. It could be quite nasty if the shaft moves right to the bottom of the hole in the outer cover (and there is nothing to stop it moving, either) - theres nothing left to hold the inner cover side thrust washer in place except the oil film. It could go down and stick to the alternator rotor magnets (if you're lucky) or it could get into the cam or balancer chains (less lucky). After that who knows what shit it could do. Worth checking.
I'm going to bring it up with Motorad and see what the position is with regard to warranty, but I wouldn't hold much hope.

is there anything tricky involved in pulling the cover off?

**Padmei** · 21st June 2010, 19:28

Originally Posted by marks

is there anything tricky involved in pulling the cover off?

Nup easy as pie. You can tip your bike over if you can't be arsed draining the oil.

**pete376403** · 21st June 2010, 20:22

Drain the oil, or tip the bike on its right side. Remove the gearlever, remove about 8 bolts securing the cover. I removed the sprocket cover (3 bolts) but you may not need to. The rotor magnet will pull the alternator coil inside the cover back in so it takes a wee bit of levering (there are tabs on the cover to get something behind, don't stick blades into the gasket face and cause future leaks) . If you are careful you should get it off without damaging the gasket. There should be four thrust washers (2 per idler gear, one each side). The top shaft doesn't have the problem, the bottom shaft does.

Wattman (of Thermobob fame) has been collating VIN numbers from contributors to KLR650.net. At present it's looking like ALL '08s and about 4000 '09s are affected - about 20,000 bikes.

**Moki** · 22nd June 2010, 19:28

Originally Posted by RedKLR650

...
You've obviously done more research on the subject so why do you suggest the trosion spring rather than the regular ones ? Both just as likely to break as the other according to my engineering friends......

Hey Stu,

I'm not an engineer, but the Torsion spring certainly seems to be a better application that keeps a pretty good pull on through the full range of adjustment. Quiets the motor down for some reason as well. Talking about springs, I also recommend the intiminators

Karl

**RedKLR650** · 22nd June 2010, 19:37

Originally Posted by Moki

Hey Stu,

I'm not an engineer, but the Torsion spring certainly seems to be a better application that keeps a pretty good pull on through the full range of adjustment. Quiets the motor down for some reason as well. Talking about springs, I also recommend the intiminators

Karl

Hi Karl, thanks for the update, and with regards to the intiminators, do you have the website where you sourced them from ?

Cheers, Stu

**Moki** · 22nd June 2010, 19:47

http://www.intiminators.com/ Late last year they were 50% off if you entered KLR650 into the coupon code field. Might have the same thing still going.

-karl

**Padmei** · 26th June 2010, 16:10

DId the starter gear check this morning.
1. Tip bike over so don't have to drain oil 200kms old.

2. Take out 10 bolts - NOT the dooickey adjustment bolt - & gently pull cover off looking out for gasket. What we are looking at is the second gear down. This can be easily pulled out & see if there is any damage to the shaft housing on the engine side. Mine was perfectly fine. There is a washer on the engine side so don't let that drop off.

3. I cut 9mm off a 10mm high tensile bolt to use as a spacer & dropped it into the deep hole with a dab of grease to hold it in while the cover is fitted. The spacer stops the starter shaft from moving across into the deep hole & dropping out of the engine side causing a clusterf**k

Let the nurse carefully scrap the silicon crap from the cover & case surface left over from the last time I opened it up- won't be doing that again.

Let the oil drain back down to the bottom of the engine & started it up. - no bad sounds so all seems good.
It should have only taken me 1/2 hr but getting the silicon crap off took about an extra 1/2 hr

pretty easy really.

**marks** · 26th June 2010, 16:32

thanks for the pictorial Padmei

Did you get sick of green or did you secretly want a tenere?

**Padmei** · 26th June 2010, 17:14

Originally Posted by marks

thanks for the pictorial Padmei

Did you get sick of green or did you secretly want a tenere?

Bit of both really. All the panels were scratched or broken & MRS Jatz' Tenere is the coolest bike around so thought I'd copy it. Any scratches from now on can be touched up really easily. Had a few strange looks from passing riders trying to work out what model yammy it is

I'm not keen on dropping it now tho- I may however not have a say in it