ds boots

[mbarney]

Dear List, I replaced the doohickey and spring yesterday on my 2005 having 1500 miles on it. Everything went smoothly, but when I got it buttoned up and thumbed the starter, I hear an occasional "whack" or knock sound. It's not continuous, but will happen after about 1/2 to 1 second of starter cranking. As soon as I heard the noise, I stopped cranking and have not run the engine since putting it back together. This morning I removed the outer crankcase cover and inspected all of the starter gears, which is where I thought the problem might be. I found no chipping or scarring on any of the gear teeth. I then rotated the engine 4 or 5 turns by hand using a socket on the rotor bolt. I heard no odd sounds. I can tell the doohickey spring is in place, but that's about all I can see. Any ideas?? I used the "lay bike on its right side" technique to avoid having to drain the oil, but was very careful not to drop anything inside the engine. I used the 38mm spring (the longer of the two supplied in Fred's kit) as it seemed tight enough. I was able to install it with fingers only, but it was snug. The stock spring was looser, but not yet slack. There was ~3mm of chain-to-case clearance after installing the new parts. I am going to pull the rotor and the inner cover next and see what I can see... Thanks for any wisdom you can provide... Matt in Boise (not the same Matt from the previous doohickey thread...

[mbarney]

I think I found my mistake. I discovered that the thrust washer that is supposed to go between the starter gear and the rotor was instead on the engine side of the rotor. There was minor scuffing occurring on the mating surface between the rotor and the starter gear. I'm working on cleaning up the gasket surfaces now, and will let you know how it sounds once I get things back together. Sorry for the panicy posting this morning! Thanks, Matt in Boise, KLR on its side in the kitchen floor.

--- In DSN_KLR650@yahoogroups.com, "mbarney" wrote: > > Dear List, > > I replaced the doohickey and spring yesterday on my 2005 having 1500 > miles on it. Everything went smoothly, but when I got it buttoned > up and thumbed the starter, I hear an occasional "whack" or knock

[el_macho650]

--- In DSN_KLR650@yahoogroups.com, "mbarney" wrote:

> > I think I found my mistake. > > I discovered that the thrust washer that is supposed to go between > the starter gear and the rotor was instead on the engine side of the > rotor. There was minor scuffing occurring on the mating surface > between the rotor and the starter gear. >

Sounds like the doohickey is hitting the starter ring gear. Every so often a bike with unlucky tolerances will have one or two of the "spokes" on the ring gear foul the edge of the doohickey. You can see where the corner of the doohickey was beveled, just remove it, and use a sharp file or grinder to remove another .5mm or so. Clean it THOROUGHLY and replace it. If you go to the doohickey page I made, there's a section on this. http://www.devonjarvisphoto.com/posted/KLR650/doohickey/ Under the Update in the "installing idler shaft lever" part. Devon

[mbarney]

Thanks Devon. I reinstalled the rotor with the thrust washer in the correct place, and that fixed it. The starter ring gear cleared the doohickey ok, but I did find some small filings where the gear contacted the rotor hub. Got my KLR put back together and out of the kitchen, then replaced the doohickey in my wife's bike. We're all happy now. Matt in Boise --- In DSN_KLR650@yahoogroups.com, "el_macho650" wrote:

> > --- In DSN_KLR650@yahoogroups.com, "mbarney" wrote: > > > > I think I found my mistake. > > > > I discovered that the thrust washer that is supposed to go

between

> > the starter gear and the rotor was instead on the engine side of

the

> > rotor. There was minor scuffing occurring on the mating surface > > between the rotor and the starter gear. > > > > Sounds like the doohickey is hitting the starter ring gear. Every

so often a bike with

> unlucky tolerances will have one or two of the "spokes" on the

ring gear foul the edge of

> the doohickey. You can see where the corner of the doohickey was

beveled, just remove it,

> and use a sharp file or grinder to remove another .5mm or so.

Clean it THOROUGHLY and

> replace it. > > If you go to the doohickey page I made, there's a section on this. > > http://www.devonjarvisphoto.com/posted/KLR650/doohickey/ > > Under the Update in the "installing idler shaft lever" part. > > Devon

[Scott Minton]

Sam, I have a pair of the Garne Explorers. They are comfortable and seem to be well made but are not as nice as some more expensive boots I've seen. They are not lined and do not appear to be very waterproof. Although I have not tested this. I have tested thier crash-worthiness however. I sprained and fractured my left ankle while way off-road out in Moab, UT. I am not blaming my injury on the boots. I doubt if any others would have prevented my injury. However I do wish I had gone with something with a bootie like the Alpinestar Tech-8. What you give up in comfort you make up in protection. If you ride mainly on road or on fire roads the Garnes should be fine. If you like more challenging off-road work you might look for something more protective. Just my $.02. Scott '00 KLR __________________________________ Do you Yahoo!? Yahoo! Mail - Find what you need with new enhanced search. http://info.mail.yahoo.com/mail_250