gearing question

[ride_happy]

2002 KLR650, 16,500+ miles, November 2003 (1 yr. 3 mos. old): My local dealer was asked to replace the stock counterbalancer chain tensioner lever with a stainless steel upgrade from Eagle Manufacturing & Engineering. This was to be preventative maintenance as I was well aware of an ongoing discussion about counterbalancer chain tensioner lever, or "doohickey," failures on the KLR list. There was also a comprehensive article about this problem in the October, 2003 issue of Dual Sport News. Upon internal inspection, the stock counterbalancer chain tensioner lever was found to be broken. When the case on the opposite side of the engine was removed to retrieve the broken tensioner lever pieces from where they were expected to be resting near a screen in the oil system, additional broken metal from another source was found. The outer race or bearing retainer on the transmission main shaft bearing had disintegrated. The bearings were still more-or-less in place and this problem was not yet apparent when operating the KLR. The counterbalancer chain tensioner lever, known on the KLR list as the "doohicky," is subject to early failure. While there may be thousands of KLRs that haven't failed, there are many that have. More alarming is the number not known to have failed until examined. The cost of early replacement is modest: maybe less than $200 if you have a shop do it; maybe a little over $100 if you do it yourself and buy all parts, tools and gaskets you need, all of which are available from Fred at Arrowhead Motorsports in Moab, UT. Comprehensive do-it- yourself articles are posted on the web by Devon Jarvis and Mark St.Hilaire. The transmission main shaft bearing failure on my KLR is apparently not a common problem. Know one knows why mine failed. There is no evidence that broken pieces from the counterbalancer chain tensioner lever contributed to this problem. Kawasaki USA generously paid for engine disassembly and replacement of the transmission main shaft bearing even though the motorcycle was out of warranty. This is my 2nd KLR. I like it and it suits my needs. I wouldn't hesitate to buy another one.

[Fred Hink]

Reading this report, I thought to myself, "this is well written". Looking at the authors name provided the answer. Nice to see you on the KLR list again Verle! Glad DSC caught your errant Doohickey before it caused other more extensive damage to your bike. I see lots of new bikes coming out of dealerships with the drive chain way too tight. Do you remember if your chain was ever on the tight side? This could be the cause of your output shaft bearing going bad. Yes, the KLR suits you and I am sure this one won't be your last either. Happy Holidays! Fred http://www.arrowheadmotorsports.com http://www.angelfire.com/ut/moab/cmc.html

----- Original Message ----- From: "ride_happy" To: DSN_klr650@yahoogroups.com> Sent: Tuesday, December 09, 2003 7:15 PM Subject: [DSN_klr650] Doohicky and more > 2002 KLR650, 16,500+ miles, November 2003 (1 yr. 3 mos. old): My > local dealer was asked to replace the stock counterbalancer chain > tensioner lever with a stainless steel upgrade from Eagle > Manufacturing & Engineering. This was to be preventative maintenance > as I was well aware of an ongoing discussion about counterbalancer > chain tensioner lever, or "doohickey," failures on the KLR list. > There was also a comprehensive article about this problem in the > October, 2003 issue of Dual Sport News. Upon internal inspection, the > stock counterbalancer chain tensioner lever was found to be broken. > When the case on the opposite side of the engine was removed to > retrieve the broken tensioner lever pieces from where they were > expected to be resting near a screen in the oil system, additional > broken metal from another source was found. The outer race or bearing > retainer on the transmission main shaft bearing had disintegrated. > The bearings were still more-or-less in place and this problem was > not yet apparent when operating the KLR. > > The counterbalancer chain tensioner lever, known on the KLR list as > the "doohicky," is subject to early failure. While there may be > thousands of KLRs that haven't failed, there are many that have. More > alarming is the number not known to have failed until examined. The > cost of early replacement is modest: maybe less than $200 if you have > a shop do it; maybe a little over $100 if you do it yourself and buy > all parts, tools and gaskets you need, all of which are available > from Fred at Arrowhead Motorsports in Moab, UT. Comprehensive do-it- > yourself articles are posted on the web by Devon Jarvis and Mark > St.Hilaire. > > > The transmission main shaft bearing failure on my KLR is apparently > not a common problem. Know one knows why mine failed. There is no > evidence that broken pieces from the counterbalancer chain tensioner > lever contributed to this problem. Kawasaki USA generously paid for > engine disassembly and replacement of the transmission main shaft > bearing even though the motorcycle was out of warranty. > > This is my 2nd KLR. I like it and it suits my needs. I wouldn't > hesitate to buy another one.

[TLrydr@aol.com]

In a message dated 12/10/2003 10:58:33 AM Central Standard Time, roclore1@... writes: << Does anyone know how many teeth on the rear sprocket equals 1 tooth on the rear. Stock gearing is 15/43. >> I havealways heard its 3 to 1 Its not exact but close,,, Exact would be like 2 1/2 to 1, I never like to go down on the front, speeds up chain and F sprocket were, a 16 40 would give you close to stock gearing, just make the chain last longer,,,, Mike