Wilsons Sandbox

08 KLR Clutch-Starter Troubleshooting #ygrps-yiv-2120009227 .ygrps-yiv-2120009227ygrp-photo-title { TEXT-ALIGN:center;WIDTH:75px;HEIGHT:15px;CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227ygrp-photo { BORDER-BOTTOM:black 1px solid;BORDER-LEFT:black 1px solid;BACKGROUND-COLOR:white;WIDTH:62px;BACKGROUND-REPEAT:no-repeat;BACKGROUND-POSITION:center 50%;HEIGHT:62px;BORDER-TOP:black 1px solid;BORDER-RIGHT:black 1px solid;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row { CLEAR:both;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row DIV { FLOAT:left;} #ygrps-yiv-2120009227 P { PADDING-BOTTOM:3px;PADDING-LEFT:0px;PADDING-RIGHT:0px;CLEAR:both;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227ygrp-file { WIDTH:30px;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227ygrp-file-title { FONT-WEIGHT:bold;} From: "Scott Marlow" To: DSN_KLR650@yahoogroups.com> Date: Wed, 4 Sep 2013 08:18:10 -0700 Subject: [DSN_KLR650] 08 KLR Clutch-Starter Troubleshooting Message-ID: 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

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<><><><><><>   Scott,   I think you have what is known as the deep hole issue.  As I understand it, some 08s, and maybe a few early 09s, had the hole for the starter reduction gear shaft in the left outer cover machined too deep.  It allows the shaft to slip to the left and then get out of alignment.  I think it's a warranty issue and should be addressed at no cost to you.  But you should allow your dealer to work that with you.  It sounds like you have a good relation with the dealer and that is more than half the battle in getting warranty issues settled.   The fix I have heard is to put a ball bearing or piece of rubber hose/tube into the hole to prevent the shaft from slipping into it further than the designers wanted.   You can probably learn more at www.klr650.net using the search function for deep hole.  I apologize now if it takes you to something inappropriate.   I think EagleMike has been including the ball bearing in doohickey kits for the 08s.   Hope this is correct and helpful.   Best, Jeff Saline The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . . . ____________________________________________________________ Fast, Secure, NetZero 4G Mobile Broadband. Try it.

08 KLR Clutch-Starter Troubleshooting #ygrps-yiv-1342651787 .ygrps-yiv-1342651787ygrp-photo-title { TEXT-ALIGN:center;WIDTH:75px;HEIGHT:15px;CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787ygrp-photo { BORDER-BOTTOM:black 1px solid;BORDER-LEFT:black 1px solid;BACKGROUND-COLOR:white;WIDTH:62px;BACKGROUND-REPEAT:no-repeat;BACKGROUND-POSITION:center 50%;HEIGHT:62px;BORDER-TOP:black 1px solid;BORDER-RIGHT:black 1px solid;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row { CLEAR:both;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row DIV { FLOAT:left;} #ygrps-yiv-1342651787 P { PADDING-BOTTOM:3px;PADDING-LEFT:0px;PADDING-RIGHT:0px;CLEAR:both;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787ygrp-file { WIDTH:30px;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787ygrp-file-title { FONT-WEIGHT:bold;} #ygrps-yiv-1342651787 .ygrps-yiv-1342651787ygrp-photo-title { TEXT-ALIGN:center;WIDTH:75px;HEIGHT:15px;CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787ygrp-photo { BORDER-BOTTOM:black 1px solid;BORDER-LEFT:black 1px solid;BACKGROUND-COLOR:white;WIDTH:62px;BACKGROUND-REPEAT:no-repeat;BACKGROUND-POSITION:center 50%;HEIGHT:62px;BORDER-TOP:black 1px solid;BORDER-RIGHT:black 1px solid;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row { CLEAR:both;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row DIV { FLOAT:left;} #ygrps-yiv-1342651787 P { PADDING-BOTTOM:3px;PADDING-LEFT:0px;PADDING-RIGHT:0px;CLEAR:both;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787ygrp-file { WIDTH:30px;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787attach-table DIV.ygrps-yiv-1342651787attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-1342651787 DIV.ygrps-yiv-1342651787ygrp-file-title { FONT-WEIGHT:bold;} Scott,   Here's a link to a thread about the deep hole.   http://www.klr650.net/forums/showthread.php?t=67886   Best, Jeff Saline The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . . . . . ____________________________________________________________ [b]Refinance at 3.38% FIXED[/b] No Points. No Fees. Zero Closing Costs! Calculate Payment. (3.38% APR) fetcharate.com

Just past half way on the KLR/Fuel and Air section. PC Racing Filter Skins PIC 18-6620     18.95 Reusable/washable allows maximum air [img]https://ec.yimg.com/ec?url=https%3A%2F%2Fwww.paypal.com%2Fimages%2Fx-click-but22.gif&t=1571809098&sig=d1FVpdDeY.UHCCYFXPjYhw--~E[/img] Fred http://www.arrowheadmotorsports.com [b]From:[/b] nomad59@... [b]Sent:[/b] Wednesday, September 4, 2013 2:27 PM [b]To:[/b] DSN_KLR650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Filter covers? (HELP! WITH NAME OF)    

Hey all   I can not find the sock like air filter cover's that I thought I got from fred, but do not see on his sight.   Just slip them on OVER the regular filter, and when dirty just replace with a clean one until home.