kill switch needed

[dirty99kawi]

Thank you all for the suggestions and tips concerning my frozen rear axle dilemma. My easiest solution was to throw the bike in my truck and bring it to Norn.  But Philadelphia is a long ways from BC.     We finally got it out. We applied Liquid Wrench, PB Blaster, and a mixture of Acetone and ATF fluid daily for the past week. Also tried heating with a propane torch.Eventually we were able to get it to turn slightly when using a socket on an 18" pry bar..By the end of the week we could get the axle to spin freely with an impact wrench, but it wouldn't slide out of the wheel. The axle was frozen onto the collar on the right side. The collar was also spinning when we turned the axle. Finally decided to we would  replace the axle, so we used brute force and a sledgehammer on the end of the axle.After several strong whacks the axle started to move. The end of the axle started to "mushroom". We used a grinder to shape the end so that it would fit. Then with a long chisel we were able to pound it all the way out. We were very happy campers by then.    Our next step is to find a used replacement axle on ebay. I'll be sure to thoroughly clean and grease everything before reassembly.

[Martin Earl]

HOOOray.!I believe Norm correctly forecast where it was 'sticking'. J4-While you are at it.Lift and remove the seals on the sealed bearing with a very thin knife and push grease into the bearing while you have all that stuff disassembled.Exercise the bearing so the grease is reaching all corners of the circle. Yeah, I hear you.I thought sealed bearings meant SEALED. cough.Having taken some recent instruction from a ~50 year off road/enduro rider/mechanic, = 70 years old, (lots of MN/SD stream crossings), he suggested to me, 'lift/remove the seals, and push grease into those 'sealed bearings' EVERY time you replace a tire, and you are likely to never replace a wheel bearing.' of course, ymmv, especially if your bike lives in a creek more than on a trail. heh! If you are not easlily finding an axle on ebay, etc. Remember you can have one in 3-5 days if you order it tomorrow from your dealer.Riding seasons (at least here) are way to short to obsess over a few bucks while looking at a 'down' machine. shrug. m1.

On Mon, Mar 23, 2015 at 6:56 PM, john4cycle@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: Thank you all for the suggestions and tips concerning my frozen rear axle dilemma. My easiest solution was to throw the bike in my truck and bring it to Norn. But Philadelphia is a long ways from BC. We finally got it out. We applied Liquid Wrench, PB Blaster, and a mixture of Acetone and ATF fluid daily for the past week. Also tried heating with a propane torch.Eventually we were able to get it to turn slightly when using a socket on an 18" pry bar..By the end of the week we could get the axle to spin freely with an impact wrench, but it wouldn't slide out of the wheel. The axle was frozen onto the collar on the right side. The collar was also spinning when we turned the axle. Finally decided to we would replace the axle, so we used brute force and a sledgehammer on the end of the axle.After several strong whacks the axle started to move. The end of the axle started to "mushroom". We used a grinder to shape the end so that it would fit. Then with a long chisel we were able to pound it all the way out. We were very happy campers by then. Our next step is to find a used replacement axle on ebay. I'll be sure to thoroughly clean and grease everything before reassembly.

[tomatocity]

Gen1 2005 KLR650 About three years ago, while it was in the garage, I broke the tip off of the Kill Switch. Now that I am putting it back on the road I want to replace the Kill Switch. Who has a Gen1 KLR650 Kill Switch that they want to sell / trade / donate? TIA Tim Olmstead Sacramento 916/837/0652

[Norm Keller]

#ygrps-yiv-1667265023 blockquote.ygrps-yiv-1667265023cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-1667265023 blockquote.ygrps-yiv-1667265023cite2 {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;margin-top:3px;padding-top:0px;} #ygrps-yiv-1667265023 .ygrps-yiv-1667265023plain pre, #ygrps-yiv-1667265023 .ygrps-yiv-1667265023plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;} #ygrps-yiv-1667265023 a img {border:0px;}#ygrps-yiv-1667265023 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-1667265023 .ygrps-yiv-1667265023plain pre, #ygrps-yiv-1667265023 .ygrps-yiv-1667265023plain tt {font-family:Tahoma;font-size:12pt;} That is what someone called the axle of evil.   Glad you got it out.   I keep waiting for someone to have to drill a swing arm bolt out. That's number infinity on the "not fun" list.