installing a second stop light

[jamiedeavers]

Hey Gang Need advice from those who have already been down this road... Just what do I have to remove to verify my balancer chain adjuster (doohickie thingie) is intact / working? Seem to have picked up a vibration around 3800 rpm and up while steady on the throttle. Not tires or such, as when clutch pulled in all is very smooth (surprisingly smooth for that matter, thought the stock tires would vibrate more than they do). Bike is a 2002 with 4k miles, only engine mods were inline fuel filter (which I removed), and turned carb screw out (re-did that too,no effect). I want to check it out myself before I head to dealer. Thanks All Jamie

[BORDER,RYAN (HP-FtCollins,ex1)]

It's real easy. I did mine for the first time in about 3 minutes, before leaving for work this morning. On the very bottom of the crank-case, on the left side, is a rubber plug, about the size of a nickel. Pry it out (I just used my fingernail), revealing the balance chain adjuster; it will look like a surprisingly small (6mm?) bolt. Loosen it a few turns, and then tighten it back up (snug, but don't crank too hard on it); your done. Pop the plug back in and go ride. Mine went click. Things are quieter. Ryan. -----Original Message----- From: jamiedeavers [mailto:jgdvrs@...] Sent: Wednesday, May 29, 2002 2:50 PM To: DSN_klr650@yahoogroups.com Subject: [DSN_klr650] Doohickie(sp?) inspection Hey Gang Need advice from those who have already been down this road... Just what do I have to remove to verify my balancer chain adjuster (doohickie thingie) is intact / working? Seem to have picked up a vibration around 3800 rpm and up while steady on the throttle. Not tires or such, as when clutch pulled in all is very smooth (surprisingly smooth for that matter, thought the stock tires would vibrate more than they do). Bike is a 2002 with 4k miles, only engine mods were inline fuel filter (which I removed), and turned carb screw out (re-did that too,no effect). I want to check it out myself before I head to dealer. Thanks All Jamie Checkout Dual Sport News at http://www.dualsportnews.com Be part of the Adventure! Visit the KLR650 archives at http://www.listquest.com/lq/search.html?ln=klr650 Post message: DSN_klr650@yahoogroups.com Subscribe: DSN_klr650-subscribe@yahoogroups.com Unsubscribe: DSN_klr650-unsubscribe@yahoogroups.com List owner: DSN_klr650-owner@yahoogroups.com Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/

[KJ]

on 5/29/02 4:54 PM, BORDER,RYAN (HP-FtCollins,ex1) at ryan_border@... wrote:

> It's real easy. I did mine for the first time in about 3 minutes, before > leaving for work this morning. > > On the very bottom of the crank-case, on the left side, is a rubber plug, > about the size of a nickel. Pry it out (I just used my fingernail), > revealing the balance chain adjuster; it will look like a surprisingly small > (6mm?) bolt. Loosen it a few turns, and then tighten it back up (snug, but > don't crank too hard on it); your done. Pop the plug back in and go ride. > > Mine went click. Things are quieter. > > Ryan.

I don't think you want to go a "few" turns. Maybe a 1/2 turn. Anyone??

[jamiedeavers]

--- In DSN_klr650@y..., KJ wrote:

> on 5/29/02 4:54 PM, BORDER,RYAN (HP-FtCollins,ex1) at

ryan_border@h...

> wrote: > > > It's real easy. I did mine for the first time in about 3

minutes, before

> > leaving for work this morning. > > > > On the very bottom of the crank-case, on the left side, is a

rubber plug,

> > about the size of a nickel. Pry it out (I just used my

fingernail),

> > revealing the balance chain adjuster; it will look like a

surprisingly small

> > (6mm?) bolt. Loosen it a few turns, and then tighten it back up

(snug, but

> > don't crank too hard on it); your done. Pop the plug back in and

go ride.

> > > > Mine went click. Things are quieter. > > > > Ryan. > > > I don't think you want to go a "few" turns. Maybe a 1/2 turn.

Anyone?? Boy...what quick responses I am familiar with the adjustment...kinda got a feeling my adjuster is not adjusting. Getting a rattling / chain-slapping sound from bottom end of motor...does not change after the adjustment is made. Now it seems I have this vibration, and maybe I'm paranoid, but I have the feeling something is amiss. FWIW-this is my first 4-stroke thumper, and have not even heard another KLR run, so really have no comparison. Thanks Jamie

[Devon Jarvis]

One turn or a little less is sufficient to release the idler shaft lever. I think the manual has a misprint- it looks like 3-4 turns when they mean 3/4 of a turn. Devon KJ wrote:

> > on 5/29/02 4:54 PM, BORDER,RYAN (HP-FtCollins,ex1) at ryan_border@... > wrote: > > > It's real easy. I did mine for the first time in about 3 minutes, before > > leaving for work this morning. > > > > On the very bottom of the crank-case, on the left side, is a rubber plug, > > about the size of a nickel. Pry it out (I just used my fingernail), > > revealing the balance chain adjuster; it will look like a surprisingly small > > (6mm?) bolt. Loosen it a few turns, and then tighten it back up (snug, but > > don't crank too hard on it); your done. Pop the plug back in and go ride. > > > > Mine went click. Things are quieter. > > > > Ryan. > > I don't think you want to go a "few" turns. Maybe a 1/2 turn. Anyone?? >

[RM]

On Wed, 29 May 2002, BORDER,RYAN (HP-FtCollins,ex1) wrote:

>On the very bottom of the crank-case, on the left side, is a rubber >plug, about the size of a nickel. Pry it out (I just used my >fingernail), revealing the balance chain adjuster; it will look like a >surprisingly small (6mm?) bolt. Loosen it a few turns, and then tighten >it back up (snug, but don't crank too hard on it); your done. Pop the >plug back in and go ride. >Mine went click. Things are quieter.

There are no guarantees that your doohickey will go "click" during adjustment. Mine never did. There are no guarantees that your engine sound will change. Mine didn't. The only way to know if the system is intact is to remove the entire left-side outer (magneto) cover. I never knew that anything was wrong until I pulled my cover off, backed off the adjuster bolt, and found a floppy doohockey. RM

[Barnaby Robson]

Hi .. Has anyone done an adjustment since installing Jake's lever barnaby? -----Original Message----- From: RM [mailto:rm@...] Sent: Wednesday, May 29, 2002 2:32 PM Cc: DSN_klr650@yahoogroups.com Subject: RE: [DSN_klr650] Doohickie(sp?) inspection

On Wed, 29 May 2002, BORDER,RYAN (HP-FtCollins,ex1) wrote: >On the very bottom of the crank-case, on the left side, is a rubber >plug, about the size of a nickel. Pry it out (I just used my >fingernail), revealing the balance chain adjuster; it will look like a >surprisingly small (6mm?) bolt. Loosen it a few turns, and then tighten >

[RM]

On Wed, 29 May 2002, Devon Jarvis wrote:

>One turn or a little less is sufficient to release the idler shaft >lever. I think the manual has a misprint- it looks like 3-4 turns when >they mean 3/4 of a turn.

Yeah. 3-4 turns is asking for trouble. Many of our bikes have no circlip to hold the doohickey in place. Back off the bolt 3-4 turns and it will allow the doohickey to cock sideways on the shaft. Re-tighten the bolt and you'll feel resistance (there should be almost NONE). Keep applying torque and in a quiet garage you'll hear a tiny "plink". That's a piece of your now-broken doohickey falling into the engine sump. Time to open the engine up. RM

[tedfshred]

My experience with freakin' doohickey: -adjusted per manual as routine maintenance 3k mi. -noticed rattle in engine about 5k -adjusted using "Carl E. technique" i.e lean to the right etc., still very noticeable rattle -bought rotor puller and holder from Fred. removed mag cover, couldn't get any "spring" action on doohickey with a screwdriver. attempted to remove big bolt from end of crank, wouldn't budge. beat on wrench with a hammer, still no budge. tested doohickey spring action again, NOW it moves back and forth, must have been bound up and freed up with beating. buttoned everything up, rattle GONE. -drove a couple hundred miles, all ok but paranoid about something amiss cuz I never got a good look at the doohickey. -opened her up again, this time had a 2 ft cheater bar, out comes the big bolt. inspected doohickey, no cracks or weird deformation, buttoned back up again. still nice and quiet. - TOO freakin quiet. paranoid valve clearance too tight. gotta get a shim kit and that video

[jamiedeavers]

--- In DSN_klr650@y..., "tedfshred" wrote:

> My experience with freakin' doohickey: > -adjusted per manual as routine maintenance 3k mi. > -noticed rattle in engine about 5k > -adjusted using "Carl E. technique" i.e lean to the right etc.,

still

> very noticeable rattle > -bought rotor puller and holder from Fred. removed mag cover, > couldn't get any "spring" action on doohickey with a screwdriver. > attempted to remove big bolt from end of crank, wouldn't budge.

beat

> on wrench with a hammer, still no budge. tested doohickey spring > action again, NOW it moves back and forth, must have been bound up > and freed up with beating. buttoned everything up, rattle GONE. > -drove a couple hundred miles, all ok but paranoid about something > amiss cuz I never got a good look at the doohickey. > -opened her up again, this time had a 2 ft cheater bar, out comes

the

> big bolt. inspected doohickey, no cracks or weird deformation, > buttoned back up again. still nice and quiet. > - TOO freakin quiet. paranoid valve clearance too tight. gotta

get

> a shim kit and that video

Yea...what you said...I just haven't got to the "quiet" part yet. Just took cover off, losened adj. bolt, adjuster would not budge at all with bolt loose(really didn't pry on it that hard) Buttoning back up now, sure I didn't accomplish a darn thing except having a look at the guts of my new machine. Jamie