Wilsons Sandbox

Hello All. I am new to the group and have been reading with interest all the exchanges on the doohickey breakage having purchased a 2002 KLR650 in February of this year. I would like to throw an idea out there that I haven t seen in any of the recent exchanges for everyone to consider. I have looked at the pictures on the web page that describes the replacement procedure for the doohickey. www.devonjarvisphoto.com/posted/KLR650/ ... ickey.html From the looks of the broken pieces, I think it is possible that another one of the KLR s personality traits may be causing the failures. I found it alarming the first time I popped the KLR into first gear after the bike sat overnight. It made a loud CRUNCH and the bike stalled from the force even though the bike was still on fast idle. I know that can t be a good thing so I now know to break the clutch plates loose before I put the bike in gear. I believe that the sticking clutch plates may be the shock that is shattering the doohickey and causing stretching of the balancer chain. On the website listed above, it shows a great picture of the complete balancer assembly under the rotor. From this picture, it appears that the balancer weights would be spinning in a clockwise direction. If the crankshaft were to suddenly decelerate due to the clutch plates sticking when the bike is put in gear, the same forces would be transferred to the balancer chain. So, you have the crank yanking on the balancer chain in one direction to slow it instantaneously and you have the centrifugal force of the spinning weights pulling the other direction because of Newton's first law, an object in motion continues in motion with the same speed and in the same direction unless acted upon by an unbalanced force. I believe the force is attempting to pull the balancer chain into a looser position by rotating the idler shaft. The only thing preventing the idler shaft from rotating is the infamous doohickey, which I believe is shattering due to the force. Are there any engineer s out there that can calculate how much force it would take to stop the rotating balancer weights instantly from 1500rpm? I bet the force applied to the balancer chain, idler shaft, and doohickey is greater than one would imagine. Call me crazy but I will be making sure the clutch plates are not stuck when I put the bike in gear. Russ Brunswick, NY __________________________________________________ Do You Yahoo!? Sign up for SBC Yahoo! Dial - First Month Free http://sbc.yahoo.com

Kurt, My Fram oil filter (CH6070) that was bought in late spring of 1999 was also made in Korea. I bought a NAPA filter (#4951) for my KLR in late summer of 2001. The packaging was similar to earlier Canadian made NAPA filters, but the package and the filter were made in Korea. In the fall, I removed this filter to take measurements of the oil filter's central tube. One of the metal end caps from the filter had separated from the filter's body. The filter still was otherwise intact, I drained the oil, and found no signs of filter debris. NAPA had 2 more filters available in their regional warehouse, one was Canadian made, the other was Korean made. NAPA's Korean made filter has more uniform folds, and passed less light than NAPA's Canadian made filter. There are some small differences in the filters' dimensions. I'm going to avoid this mess entirely by ordering one of Fred's lifetime stainless steel filters. Newbie notes: When the oil level in the inspection window is in the middle, you need to add 1/2 qt. to bring the level up to the top of the window. You need to add a full quart of oil if the oil level is near the bottom of the window. Both measurements were taken after my KLR sat overnight and the bike was fully upright. I've also noticed that the engine noise is noticeably louder when the (overnight) oil level drops by 1/3 in the window. I've also noticed that the engine noise at start up is somewhat quieter if my KLR is started in the full upright position. I haven't needed any of the replacement o-rings (yet) after 6 oil filter changes. Does anyone know what the proper oil level is? Professor A9 Federal Way, WA. [USA] ++++++++++ Kurt replied:

> I just bought a Fram CH6070 at Cycle Parts West in San > Diego and it is labeled made in Korea. First time I've seen > this, looks just like the Canadian version I've purchased in > the past. > Kurt Grife

---------- pcoast2002@y... writes:

> > NAPA #4951 > > Wix #24951 > > Fram #CH6070 > > All three are made by the same manufacturer in Canada. > > All three come with O-rings.