smashed chain guide?

DSN_KLR650
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Stuart Mumford
Posts: 1178
Joined: Tue Apr 11, 2000 6:45 pm

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Post by Stuart Mumford » Wed Nov 28, 2001 9:06 pm

I expect the gaskets within the next day or 2. I can't see how yours could have fell off unless it was broken, man. The shaft (39115) it rides on is buried into the magneto cover on the end it can slip over. The snap ring (480) retains the sprocket (39133) in place on the shaft (39115). Where did you get that magneto puller? CA Stu -----Original Message-----
On Wed, 28 Nov 2001, Tengai650 wrote: >3) because most KLRs don't have a circlip retaining the idler lever (the >600 and some early 650s and the '89 Tengai had a circlip) and the bike >is leaning to the left, gravity causes the over-loosened idler lever to >slide off the shaft a little (like 1/2 mm) Stu, I backed my bolt out too far in a "what does this do" moment of stupidity and my idler lever FELL OFF. No circlip on my A14. THIS is why I own those tools that I lent you. I had to put the little turd put back on the shaft where it belongs. I do like your idea, though. Last time I did the adjust, I felt quite a bit of resistance when turning the bolt back in, like the idler lever tried to slip off and was forced back on when I re-tightened. I'm getting all itchy to take a looksee at my doohickey now. When is the gasket supposed to arrive? RM
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Stu
Posts: 399
Joined: Wed Dec 20, 2000 5:03 pm

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Post by Stu » Wed Nov 28, 2001 9:14 pm

I uploaded a jpg from buykawasaki.com to the "Photos" section to refer to to see the balancer part numbers. hey listmaster the files section is full, could ya clean it up a bit? Thanks CA Stu
--- In DSN_klr650@y..., "Stuart Mumford" wrote: > I expect the gaskets within the next day or 2. > > I can't see how yours could have fell off unless it was broken, man. > The shaft (39115) it rides on is buried into the magneto cover on the end it > can slip over. > The snap ring (480) retains the sprocket (39133) in place on the shaft > (39115). > > Where did you get that magneto puller? > > CA Stu > > -----Original Message----- > > > On Wed, 28 Nov 2001, Tengai650 wrote: > > >3) because most KLRs don't have a circlip retaining the idler lever (the > >600 and some early 650s and the '89 Tengai had a circlip) and the bike > >is leaning to the left, gravity causes the over-loosened idler lever to > >slide off the shaft a little (like 1/2 mm) > > Stu, I backed my bolt out too far in a "what does this do" moment of > stupidity and my idler lever FELL OFF. No circlip on my A14. THIS is why > I own those tools that I lent you. I had to put the little turd put back > on the shaft where it belongs. > > I do like your idea, though. Last time I did the adjust, I felt quite a > bit of resistance when turning the bolt back in, like the idler lever > tried to slip off and was forced back on when I re-tightened. > > I'm getting all itchy to take a looksee at my doohickey now. When is the > gasket supposed to arrive? > > RM
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Richard Ohnstad
Posts: 140
Joined: Mon Jun 12, 2000 3:27 pm

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Post by Richard Ohnstad » Wed Nov 28, 2001 11:15 pm

I think Mark possibly has the right theory. When I was doing the balancer upgrade and had the outer cover off, I did mess around with the bike on the sidestand, loosening up the adjuster bolt a turn or two, and the LEVER, IDLER SHAFT would start to fall off the shaft. Then when you retighten, the LEVER, IDLER SHAFT would get cockeyed on the shaft. It is a shitty design!!! Rich in Tucson 94 KLR650 86 VFR750
> At 12:27 AM +0000 11/29/01, Stu wrote: > >In a nutshell, this is exactly what I think caused all the failures. > >My idler shaft lever has some scarring on it; I'm sure I > >overtightened the idler lever bolt thereby damaging and weakening the > >idler shaft lever, because I am a bonehead. > > I don't think so, as the area that breaks is not the area that > receives pressure from tightening. > I think that over-loosening may actually be the source. > Here's my theory: > 1) Owner parks bike on sidestand > 2) owner loosens keeper bolt several turns instead of the 3/4 to 1 turn
needed
> 3) because most KLRs don't have a circlip retaining the idler lever > (the 600 and some early 650s and the '89 Tengai had a circlip) and > the bike is leaning to the left, gravity causes the over-loosened > idler lever to slide off the shaft a little (like 1/2 mm) > 4) owner then tightens the keeper bolt. > 5) the base of the lever gets pressed and tightened against the > engine case, but the lever doesn't slide back up the shaft. This > causes a prying tension in the lever where it wraps around the shaft. > 6) eventually, the combination of engine vibration and the induced > tension causes the hardened-steel (brittle, not maleable) lever to > shatter as shown: http://www.personal.psu.edu/mjv2/IdlerLever.jpg > Mark
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RM
Posts: 1977
Joined: Tue May 09, 2000 7:20 pm

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Post by RM » Thu Nov 29, 2001 12:55 pm

On Wed, 28 Nov 2001, Stuart Mumford wrote:
>Where did you get that magneto puller?
Fred.
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guymanbro@excite.com
Posts: 498
Joined: Fri May 05, 2000 2:51 am

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Post by guymanbro@excite.com » Sun Dec 02, 2001 11:51 am

Where exactly did yours break? Mine broke on the shaft hole not the bolt slider slot. No evidence of stripping on mine. Definitely gonna pull the mag cover from now on. dat brooklyn bum
--- In DSN_klr650@y..., "Stuart Mumford" wrote: > No evidence of stripping, but the bottom of the broken piece has some scarring on it where it looks like I overtightened the adjustment bolt. > > I think the best option is to pop off the magneto cover when adjusting this mechanism, so you can see exactly what the heck is going on in there. > > CA Stu > > -----Original Message----- > From: Bogdan Swider [mailto:BSwider@C...] > > > I think we each may have overtightened the balancer chain adjustment screw. I reckon this is why mine let go. > > > Any sign of stripping or was the evidence missing. > > Bogdan
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steve secrest
Posts: 37
Joined: Wed May 03, 2000 7:44 pm

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Post by steve secrest » Sun Dec 02, 2001 11:56 am

Mine broke at the shaft hole also ... looks like adjuster slides on shaft when bolt is loosened, binds there, tighten bolt and wait for breakage whilst riding. Parts will be here any day and I'm gonna test this theory ... will report back Steve in Cincy
> Where exactly did yours break? Mine broke on the shaft hole not the > bolt slider slot. No evidence of stripping on mine. Definitely gonna > pull the mag cover from now on. > > dat brooklyn bum
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Stu
Posts: 399
Joined: Wed Dec 20, 2000 5:03 pm

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Post by Stu » Mon Dec 03, 2001 1:14 am

Mine too. Picked up parts Friday afternoon, replaced Saturday morning, runs quiet and smooth now, like a 2 wheeled Rolls Royce. For the record, my old geezer says "Rolls Royces never break down. They "fail to proceed."". Maybe welding the slider solt to the shaft sleeve weakens the sleeve sometimes? Who knows, either way , a billet piece would solve this problem, methinks.... Hellooo , Big Cee ??? CA Stu A13 --- In DSN_klr650@y..., "Steve Secrest" wrote: > Mine broke at the shaft hole also ... looks like adjuster slides > on shaft when bolt is loosened, binds there, tighten bolt and > wait for breakage whilst riding. Parts will be here any day > and I'm gonna test this theory ... will report back > > Steve in Cincy > > > > > Where exactly did yours break? Mine broke on the shaft hole not the > > bolt slider slot. No evidence of stripping on mine. Definitely gonna > > pull the mag cover from now on. > > > > dat brooklyn bum
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