KLR riders out there

**Padmei** · 11th June 2010, 16:58

No need for new gaskets or rotor bolt if you're careful they'll be fine.
Apparently heading down to hamner way 16th July so bro inlaw can take tools down to chch.

**RedKLR650** · 11th June 2010, 17:24

Originally Posted by Crim

Thanks guys - it was actually the dusty butt round your neck of the woods that got me thinking ".............. bout time........" will order parts online and see you in early August Padmei - if the parts get here before then - you never know! I may get too impatient and PM my address. I can't wait - there are some good videos online running you through the whole process and doesn't look too scary - touch wood (or a Nordie patented sump plug) I don't hit a snag
'nother question now that I have done some searching (hindsight 20/20 per normal) - gaskets and rotor bolt order new?

Hi Crim,

I'm based in Timaru and have the Doohickey Kit and Tools and am about to do the upgrade but I am also just about to order the more powerful aftermarket Lighting Stator ( Thing that generates power for the Battery ) from the states as it's inside the casing you have to take off to do the doohickey so figure I may as well change it at the same time :-)

Anyway, I'm Timaru based but am currently 11 days into a 90 day Demerit Point suspension so it's a good time to do the work, but I am unable to travel to Chch with the bike. If however you want to travel down here, it may be useful for us to work on the 2 bikes at the same time and I also have the tools etc. Give me a buzz on 0 3 688 5050 or 0274 342 372

Just an idea......

cheers, Stu

**Crim** · 11th June 2010, 21:03

Originally Posted by Padmei

No need for new gaskets or rotor bolt if you're careful they'll be fine.
Apparently heading down to hamner way 16th July so bro inlaw can take tools down to chch.

G'day Padmei,
Thanks for the offer - been in contact with Stu out of Timaru, he has the tools so we are going to get the Doos and have a workshop day in Timaru - at least it will give me a decent before and after ride to compare differences - I will make sure we get photos of both set ups when we get into them
Cheers Crim

**Woodman** · 11th June 2010, 21:04

It will be interesting to see whether your guys doos are broken or not. my lever was fine but the spring was broken and flopping around in there.

just holler if you want the torsion spring.

**Crim** · 11th June 2010, 21:07

Originally Posted by Woodman

It will be interesting to see whether your guys doos are broken or not. my lever was fine but the spring was broken and flopping around in there.

just holler if you want the torsion spring.

be jasus that was quick - was going to give you a holler and see if you still had that floating around, as we were both thinking of putting the torsion springs in as well - why didn't you put yours in?

**Woodman** · 11th June 2010, 21:25

Originally Posted by Crim

be jasus that was quick - was going to give you a holler and see if you still had that floating around, as we were both thinking of putting the torsion springs in as well - why didn't you put yours in?

You have to drill a hole in the case for one end of the spring to go in, and the drill bit broke off and is still in there so I put the other one on instead.
Man that drill bit sure makes the bike heavy in the gnarly stuff.

I will get it out this weekend and get it to Padmei before he goes to Hamner, or I can send it. You choose.

**Padmei** · 11th June 2010, 21:30

Originally Posted by Woodman

You have to drill a hole in the case for one end of the spring to go in, and the drill bit broke off and is still in there so I put the other one on instead.
Man that drill bit sure makes the bike heavy in the gnarly stuff.

I will get it out this weekend and get it to Padmei before he goes to Hamner, or I can send it. You choose.

I think it'll be stuffed by now woodman. He can surely afford a new drill bit???

**Woodman** · 11th June 2010, 21:35

Originally Posted by Padmei

I think it'll be stuffed by now woodman. He can surely afford a new drill bit???

I was just about to edit that just in case in someone misread it and thought I was referring to the drillbit and not the spring.

But for claritys sake, I will get the torsion spring out and get it to Padmei yada yada yada

**RedKLR650** · 11th June 2010, 23:00

Originally Posted by Woodman

It will be interesting to see whether your guys doos are broken or not. my lever was fine but the spring was broken and flopping around in there

I'll be sure to post photos of both. I'm curious myself, 36,000 hard kms on the clock for mine now.....

**Woodman** · 11th June 2010, 23:33

Originally Posted by RedKLR650

I'll be sure to post photos of both. I'm curious myself, 36,000 hard kms on the clock for mine now.....

Done mine after about 26,000kms of gentle riding.

Certainly quitened it down.

**pete376403** · 19th June 2010, 17:40

Another thing for us '08 & '09ers to worry about - the hole that the starter idler gear shaft goes into, in the outer engine cover, is too deep in some engines. If the shaft moves too deep into the outer cover, it becomes unsupported in the inner cover (which is bad) and it can let shim washers drop out (which could be very bad). It's a cheap and easy fix (pull the cover, drop a spacer into the too deep hole, refit the cover) but worth doing as the early '08s are out of warranty and it has the potential to grenade the motor. I read about this here http://www.klr650.net/forums/showthread.php?t=67886 and will be checking my bike tomorrow.

**Padmei** · 19th June 2010, 18:44

Interesting. I had to read about 11 bloody pages until Wattman put a diagram up. As you said pete an easy fix for a potential blow up.

Here's the problem Post #158
http://www.klr650.net/forums/showthr...=67886&page=11

Eaglemike is making 10mm spacers about 10mm deep & selling them (really - no joke)