KLR riders out there

[pete376403]

Did the deep hole fix today - a .375 ball bearing is perfect. Oil film was enough to hold it in the hole and there's .020 clearance (+ gasket thickness) between it the ball and the shaft when assembled.
That was the cheap fix. The more expensive fix will be new chain and front sprocket (only lasted 20,000k). Will go down a tooth at the front, do aftermarket sprockets have the rubber damping rings like the standard part? Does it make a difference?
Anyone done anything in the way of rebuilds with the standard rear shock?

[Woodman]

Did the deep hole fix today - a .375 ball bearing is perfect. Oil film was enough to hold it in the hole and there's .020 clearance (+ gasket thickness) between it the ball and the shaft when assembled.
That was the cheap fix. The more expensive fix will be new chain and front sprocket (only lasted 20,000k). Will go down a tooth at the front, do aftermarket sprockets have the rubber damping rings like the standard part? Does it make a difference?
Anyone done anything in the way of rebuilds with the standard rear shock?

My after market sprockets do not have the rubbery bit and work fine, no difference that I have noticed.

[Padmei]

After doing the 14 tooth thing with the front sprocket I have gone back to the 15 & use the clutch a lot more. The 14 is just a bit too buzzy on the road - ok for short bursts but long trips...
I hear you with the front sprocket & chain. I don't know how experienced you are at changing chains but mine now has 3 joiner links in it after trying to get it on thefirst time. Definitely something I won't have a problem taking to the shop to do next time.
My 14 didn't have the rubber damping ring & don't really know why they're there.

Rebuild your rear shock? Just get a Ricor or moab - prob better & cheaper in the long run.

[Woodman]

Just remembered, I got my rear shock re gassed a while ago. Not really sure if it made any difference or not, but am happy with the rears performance really.

[pete376403]

This is one of the items I saw about shock rebuilding - http://calgarydualsport.tripod.com/k...procedure.html
The seal head I have seen listed at one of the off road accessory places in NZ - will try to locate, previously advertised on KB http://www.bits4bikes.co.nz/parts/ka...erms=seal+head
and one other shock rebuild article added a remote reservoir from a polaris ATV

[Howie]

Did the deep hole fix today - a .375 ball bearing is perfect. Oil film was enough to hold it in the hole and there's .020 clearance (+ gasket thickness) between it the ball and the shaft when assembled.
That was the cheap fix. The more expensive fix will be new chain and front sprocket (only lasted 20,000k). Will go down a tooth at the front, do aftermarket sprockets have the rubber damping rings like the standard part? Does it make a difference?

Hi Pete, I replaced my front sprocket with an aftermarket one (no rubber damping ring)at about 21000km. I didn't bother changing the chain or rear sprocket. The front sprocket was showing a large amount of wear, yet the back was fine. The chain didn't have any tight spots in, and hadn't needed much in the way of adjustment, I'm now at about 28000km, and they are all still fine although I am keeping more of an eye on the chain. The rubber ring is only there to reduce chain noise from the research I did on the net.

[marks]

Did the deep hole fix today - a .375 ball bearing is perfect. Oil film was enough to hold it in the hole and there's .020 clearance (+ gasket thickness) between it the ball and the shaft when assembled.

errr - whats the deep hole fix?
sounds like something a dr rider would do after his boyfreind got a bit carried away.

Pete - I'm running a 16T on the front and am very happy with it - makes a big difference at 110-120.

My chain and sprockets lasted about 21000 - seems about average.

[pete376403]

Deep hole fix - dropping something of suitable size into the hole that is too deep in the generator cover as per Padmeis post and pictures.

Whats the VIN number of your bike (last five digits) - it looks like all '08s have the problem and about 4000 of the first '09s. VINs restarted for the '08s at 00001 (mine is 01831) and continued into the '09s at about 18000. The problem appears to have been rectified by the factory at around VIN21000 with a different part number generator cover.

[marks]

Deep hole fix - dropping something of suitable size into the hole that is too deep in the generator cover as per Padmeis post and pictures.

Whats the VIN number of your bike (last five digits) - it looks like all '08s have the problem and about 4000 of the first '09s. VINs restarted for the '08s at 00001 (mine is 01831) and continued into the '09s at about 18000. The problem appears to have been rectified by the factory at around VIN21000 with a different part number generator cover.

looks like I have a problem with a 'deep hole' (you confused me by talking about shocks in the same thread)
I'm in the affected range (16112) so I spose I'd better have a look

[Padmei]

Picked up the R1 pipes from Filco today. Tried one on the KLR & sounds superb. It's not very loud at idle but has a nice lower note, when the revs get up there's no poot poot like the stock. Also about 20kilos lighter than the stock. A few brackets welded on & a bit of pipe work & it'll be sitting pretty. I'll prob use the other one on the BMW. Not bad for $175 for both.

[pete376403]

What model R1? Is this a standard R1 can or an aftermarket one? Have much trouble matching it up to the KLR header?

[Woodman]

Picked up the R1 pipes from Filco today. Tried one on the KLR & sounds superb. It's not very loud at idle but has a nice lower note, when the revs get up there's no poot poot like the stock. Also about 20kilos lighter than the stock. A few brackets welded on & a bit of pipe work & it'll be sitting pretty. I'll prob use the other one on the BMW. Not bad for $175 for both.

I knew you wouldn't be able to resist.

[Padmei]

What model R1? Is this a standard R1 can or an aftermarket one? Have much trouble matching it up to the KLR header?

A standard can- I'm not sure what year . Someone got a flash set put on & left these ones at the bike shop. They will need a couple of brackets welded onto them to fit the mounting holes & some pipe welded & bent a bit to fit to the header but I've got a mate who's an exhaust specialist that needs some wiring done ina few weeks so it will be a cheap fix.
If I didn't have welding contacts (no pun intended) I wouldn't have bothered but they look very nice & sound really really nice. Not Ear bleeders like Marks Jardines.

I knew you wouldn't be able to resist.

Bloody Chae the bastard - he knew as soon as I saw them I'd be taking them.

[Padmei]

Here's a pic of the cans. I swear the stocker must be 20kilos - unbelievably heavy in comparison. I had to slide the new one on again & start the bike up before work just to hear the beautiful sound

[Willdat?]

That's really going to suit Gonzo well...even more Yamaha in it's DNA!