08 klr clutch-starter troubleshooting

[secarver7]

My 2008 had intermittant starter issues. It would crank quickly for a few cycles, then slow, as if it was binding. Sometimes there was a loud howl. Finally, it quit starting. (Starter motor would spin, but engine did not). One of my starter gears had come loose on the shaft.   Turns out there is a known issue with the early 2008's. the hole in the side plate was drilled too deeply.  The starter gear shaft would migrate into the deep hole and only support the starting gear on one side. After intermittant seizing, a gear would break or begin spinning on the shaft.   The fix is simple. drop a chunk of metal in the too-deep hole so the starter gear shaft remains supported on both sides. I wedged the chunk in with foil so it wouldn't fall out in future disassembly. -hope it helps,  scott carver 661,201.8558.

--- In DSN_KLR650@yahoogroups.com, dsn_klr650@yahoogroups.com> wrote: 08 KLR Clutch-Starter Troubleshooting This past December, my local Kawasaki shop had to repair the clutch-starter on my 2008 KLR (~25,000 miles). Symptoms On bike startup intermittently - but frequently - I was hearing a very loud 'K-thunk' - as if the bike was starting/'catching' in gear (but it was always in Neutral). Problem An approx. ~1/8" "part of the secondary reduction gears case had been broken". (I WISH I had taken a picture). Repair This involved draining the case; replacing the generator case cover, 2 gaskets, shaft idler, and some washers and bearings ($285 + labor). The problem disappeared until a couple weeks ago when it resurfaced L The dealer has offered to open the clutch case to inspect and promise to "make it and treat me right." The shop had never seen or heard of such an issue, and they could not determine what caused the problem. In fact, they had to find some parts on eBay because it was so difficult to procure them. I'm concerned why this issue has sprung up again. Any ideas? Could this be some type of 'lemon' issue? Maybe something in the clutch-starter that was missed and also needed to be replaced? Some foreign object in the oil? Sorry, I can't be more specific - but this type of issue is way above my meager mechanical skills. Obviously, I don't want to keep pouring repair $$ into a 5-year old KLR with 28k miles. Any tips appreciated. -- Scott Marlow (206) 784-5454

[josephgrove42]

I often ride to work and stop by for a cup of coffee and pastry to take to the office, or after lunch at a fast food place, I want to take a drink back to the office. The problem? Where to put them while I ride. I went looking for a cup-holder I could in some way adapt to my KLR. I found it among the bicycle accessories. Bell makes one to attach to bicycle handle bars. It is just a mental ring to set the cup in and it works well. It will mount to the KLR handle bars on the left side right next to the mirror mount. Works great. Joe Grove Issaquah, WA