Wilsons Sandbox

If it was me, I would pull the caliper of the bike, but leave the brake line attached. Mash the lever, or pedal, to pop the cylinder out of the caliper. Clean up as needed, get a new seal, and slap it back together. Heck, I took a caliper off my 1975 CB360 about 6 years ago because it was locking up. I cleaned it up and slapped it back together. I didn't even replace the seal. Has not failed since. Rick A17

--- On Wed, 8/12/09, Logan wrote: From: Logan Subject: [DSN_KLR650] Rear Caliper for 03 KLR To: DSN_KLR650@yahoogroups.com Date: Wednesday, August 12, 2009, 1:55 PM Hi KLR'ers, My 03 rear caliper has seized up. I have been looking online for just about a week for a replacement caliper, but other than a few expensive ones I have not seen anything. Anyone out there have one or know of a reasonable place I could purchase one? Thanks for any assistance Slainte Logan in Victoria, BC, [Non-text portions of this message have been removed]

I agree with Rick. Some possible causes of the caliper seizing are discussed on this web page: http://home.insightbb.com/~mmartin36/Caliper.htm HTH, Mike Martin, Louisville, KY ________________________________ From: Rick McCauley If it was me, I would pull the caliper of the bike, but leave the brake line attached. Mash the lever, or pedal, to pop the cylinder out of the caliper. Clean up as needed, get a new seal, and slap it back together. [Non-text portions of this message have been removed]

On Thu, 13 Aug 2009 16:46:00 -0000 "hgyrmliun" writes:

> There seem to be two ways of changing the fork oil (without removing > the forks from the bike)and I'd like to know which is best. One is > to measure 355 ml of oil and pour it in--which seems nice and easy. > The other way is to measure the level--which is also easy but I > can't figure out how to compress the forks all the way with the bike > on the lift. > Am I safe in just pouring in the 355 ml,sealing things up,and saying > thats' that? > > David > 2006 KLR650 > New York

<><><><><><><><><><> <><><><><><><><><><> David, My suggestion is to stabilize the bike so you can remove the front wheel. Then you can compress the forks as desired to adjust the level. Maybe consider some blocks of wood under the skid plate or set the bike on a milk crate like device. I use 190mm from the top with the fork compressed to adjust the oil level. We had that discussion in May and it was suggested Kawasaki returned to the 170mm level sometime after 2003 but I haven't seen any hard facts about that. If you aren't going to make it where you can compress the forks probably pouring in the same amount you drain out will work. If you do set the bike up so you can compress the forks, pumping the forks with the drain plug out will probably get a few more cc's of fluid from each fork. Then make sure you pump the forks a few times before adjusting the oil level. I understand on post 08 KLRs the forks don't have a drain plug so you must remove the forks to drain them. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________________________________________________________ Click to learn how to become a world famous writer or poet. http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTIZkWVHGrrRPrCwnliVfVjqBfDHlyBli6KYPschVIDPKBfJhh0n7K/

Just do as the other guy said and pop the piston our and cleaN it with alchol or suitable cleaner.Mine was dirty like that on the front and froze up. How do you pop the pistons out onultiple piston caliphers like my Concourse has? Criswell Sent from my iPhone

On Aug 12, 2009, at 1:55 PM, "Logan" wrote: > Hi KLR'ers, > > My 03 rear caliper has seized up. I have been looking online for > just about a week for a replacement caliper, but other than a few > expensive ones I have not seen anything. Anyone out there have one > or know of a reasonable place I could purchase one? > > Thanks for any assistance > > Slainte > > Logan in Victoria, BC, > > [Non-text portions of this message have been removed]