simple question from a newbie

[Thane Silliker]

KLRistas, Has anyone done the KLR oil light mod. By this I mean using the blank idiot light location. Any online pics or How-tos? I plan on adding an oil pressure guage over the winter, but I am curious about this mod. Thane London, Ontario

[Jeff Saline]

On Sat, 19 Nov 2005 19:36:57 -0500 Thane Silliker writes:

> KLRistas, > > Has anyone done the KLR oil light mod. By this I mean using the > blank > idiot light location. > > Any online pics or How-tos? > > I plan on adding an oil pressure gauge over the winter, but I am > curious > about this mod. > > Thane > London, Ontario >>>>>>>>>>>>>>>>>>>>>>>

Thane, I haven't heard of anyone doing that yet. A few times I've heard of folks requesting info about it and talking about where to hook up a sending unit. I seem to recall someone considering putting a sending unit at a banjo fitting on the right side of the bike. But I'm not sure. I suppose a guy could tap into the oil filter housing and mount it there. I just took a look in the factory service manual and for 2002-2003 models it suggests the oil pressure should be 11-21 psi @ 4,000 rpm @ 194 degrees F. It doesn't say where that measurement is taken. I'll be interested in hearing where you decide to put a sending unit and what kind of pressure it's set for. Also I'm interested in the actual oil temp as some of Bill Watson's coolant data indicate the oil on a stock KLR might not get up to 194F very often. If that in fact is true then the oil pressure will probably be a bit different from the specifications in the book. So when do you want the light to go out? Or more importantly, when do you want the light to come on? The wiring should be pretty easy as I think all you'll have to do is supply positive voltage to the light bulb and have negative voltage go to the sending unit. Looking forward to hearing how it goes. Best and good luck, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT

[Jeff Saline]

Thane, I have used that to help drain the filter housing when changing the oil filter. I'd be concerned using that location as it seems too close to rocks etc. Even with a good skid plate. But I sure hope it works well for you. I'll be interested in hearing how it goes. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT On Sat, 19 Nov 2005 21:26:21 -0500 Thane Silliker writes:

> There is a fitting under the engine. When looking at the right side > of the > engine, find the oil filter cover. Follow a vertical bulge down to > the > bottom of the engine. There is a threaded cap there. This is where > I will > be tapping into for the oil pressure. > > Thane > > > At 08:50 PM 19/11/2005, Jeff Saline wrote: > > oil pressure should be 11-21 psi @ 4,000 > >rpm @ 194 degrees F. It doesn't say where that measurement is > taken. > > > >

[dumbazz_650]

Never done it, but I would rather use a double banjo bolt to tap the oil feed line that come out the top of the case and feeds the head. At least it would be protected there. Besides, the head is at the end of the oil distribution line and it would seem to be the best place to begin testing for low pressure. Tnx, MarkB

--- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote: > > Thane, > > I have used that to help drain the filter housing when changing the oil > filter. I'd be concerned using that location as it seems too close to > rocks etc. Even with a good skid plate. But I sure hope it works well > for you. > > I'll be interested in hearing how it goes. > > Best, > > Jeff Saline > ABC # 4412 South Dakota Airmarshal > Airheads Beemer Club www.airheads.org > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650, 79 R100RT > > On Sat, 19 Nov 2005 21:26:21 -0500 Thane Silliker > writes: > > There is a fitting under the engine. When looking at the right side > > of the > > engine, find the oil filter cover. Follow a vertical bulge down to > > the > > bottom of the engine. There is a threaded cap there. This is where > > I will > > be tapping into for the oil pressure. > > > > Thane > > > > > > At 08:50 PM 19/11/2005, Jeff Saline wrote: > > > oil pressure should be 11-21 psi @ 4,000 > > >rpm @ 194 degrees F. It doesn't say where that measurement is > > taken. > > > > > > > > >

[Thane Silliker]

There is a fitting under the engine. When looking at the right side of the engine, find the oil filter cover. Follow a vertical bulge down to the bottom of the engine. There is a threaded cap there. This is where I will be tapping into for the oil pressure. Thane At 08:50 PM 19/11/2005, Jeff Saline wrote:

> oil pressure should be 11-21 psi @ 4,000 >rpm @ 194 degrees F. It doesn't say where that measurement is taken.

[Thane Silliker]

Very wise. At 09:53 PM 19/11/2005, dumbazz_650 wrote:

>Never done it, but I would rather use a double banjo bolt to tap >the oil feed line that come out the top of the case and feeds the >head. At least it would be protected there. > >Besides, the head is at the end of the oil distribution line and it >would seem to be the best place to begin testing for low pressure.

[Bill Watson]

Thane, Jeff and Mark, About 6 months ago, I was discussing this with Norm Keller - Norm wanted to test via a banjo fitting but hasn't gotten around to it yet. However, I have tested through the bottom port as Thane mentioned... Jeff, you're right about the spec of oil pressure at 4000 rpm and 194F, but the manual does show this very location on page 4-14 of the base manual as where to test. I agree with Jeff, it would be a breeze to do in terms of wiring - a 12V supply to the bulb, and the grounding wire to the pressure sender. The question of what pressure to have the light come on.... well, I'll attach two .JPEG files for a few of you, and if anyone wants them, just send me an e-mail at gcurve2000@..... If you look at the plots, I would recommend an idiot sender of 3 to 5 psi. Once my bike was warmed up on a 70 degree day, it had about 8 psi of oil pressure at 1,000 rpm and 16 psi at 4,000 rpm (and a pretty straight line in-between). The oil was about 180-190F measured at that same port. On a really hot day (105-110F) I rode more aggressively and the oil was 230F. At 1,000 rpm, oil pressure was 5-6 psi. Thus the recommendation of 3-5 psi. I would suggest we're looking for a total failure of the system (like a pump failure or failure of the right crank end seal). Since these bikes run 5-70 psi all the time depending on conditions, having a light trigger any higher will have you staring at a red light every day after the bike warms up. As for location, agreed it's the most vulnerable. Depends on how aggressive you are off road and how strong your skidplate is and how far it must deflect to even contact an installed sensor. If you install it on the banjo bolt, tell us what fittings you used to make it happen. And although I agree with Mark B about the lowest pressure location being the right exhaust cam bearing, that it would take some machine work to actually get a probe in there, plus I think we're just looking for "total failure" since that location is clearly equal to or lower than the pressure's I've already measured, and they're quite low. Bill Watson Phoenix writes:

> KLRistas, > > Has anyone done the KLR oil light mod. By this I mean using the > blank > idiot light location. > > Any online pics or How-tos? > > I plan on adding an oil pressure gauge over the winter, but I am > curious > about this mod. > > Thane > London, Ontario >>>>>>>>>>>>>>>>>>>>>>>

Thane, I haven't heard of anyone doing that yet. A few times I've heard of folks requesting info about it and talking about where to hook up a sending unit. I seem to recall someone considering putting a sending unit at a banjo fitting on the right side of the bike. But I'm not sure. I just took a look in the factory service manual and for 2002-2003 models it suggests the oil pressure should be 11-21 psi @ 4,000 rpm @ 194 degrees F. It doesn't say where that measurement is taken. The wiring should be pretty easy as I think all you'll have to do is supply positive voltage to the light bulb and have negative voltage go to the sending unit. --------------------------------- Yahoo! FareChase - Search multiple travel sites in one click. [Non-text portions of this message have been removed]

[Jeff Saline]

Bill, Listers, Thanks for the plots of the oil pressures. Very interesting and helpful. I'm thinking the light might really be a fix to a problem that doesn't exist. : ) But, if it's gonna get done I've got another thought or two about this. I wandered out to the shop for a minute this morning and took a peek at my KLR. I have a Dual Star metal skid plate and it looks like there is enough room behind it to put a sender at the test point. My KLR has seen a few rocks and logs etc and the plate is in fine shape there. I might be concerned if I was going into a brush pile or riding through a logging area. All it would take is one good hard poke to cause a problem. Having a two prong sending unit could be a fail safe. Have voltage going from the light to the sender and then a wire from the sender to ground. If the sender got busted off the engine (and the wires didn't get disconnected) it wouldn't have pressure and the light would light. But, I'm pretty sure I wouldn't be looking at the dash in that situation. Also, looking at the plots I'm thinking a 10 psi sender might be ok if a guy didn't mind seeing the light at idle or low rpms once the engine gets to operating temperature. It looks like 10 psi would cover everything above 2,000 rpm once the bike gets warmed up. Most of my riding is above 2,000 rpm and if I'm at slow speeds I'm probably too busy looking at other stuff to notice a dash light. On the BMW Airheads the oil light comes on somewhere around 3-7 psi depending on who you talk to. Lots of us joke the light should have a $ sign over it cause when it comes on, expensive damage has already been done. So maybe if the light came on a bit sooner at higher rpms a guy could save a camshaft or two by taking quick action. Bill, I'm also interested in learning a bit more about the instrumentation you use to collect your data for this and the coolant testing you've done. Something tells me it's a bit more than a gauge and a pencil and paper while riding down the road. : ) Thanks again and Best, Jeff On Mon, 21 Nov 2005 20:52:15 -0800 (PST) Bill Watson writes:

> Thane, Jeff and Mark, > > About 6 months ago, I was discussing this with Norm Keller - Norm > wanted to test via a banjo fitting but hasn't gotten around to it > yet. However, I have tested through the bottom port as Thane > mentioned... Jeff, you're right about the spec of oil pressure at > 4000 rpm and 194F, but the manual does show this very location on > page 4-14 of the base manual as where to test. > > I agree with Jeff, it would be a breeze to do in terms of wiring - > a 12V supply to the bulb, and the grounding wire to the pressure > sender. The question of what pressure to have the light come on.... > well, I'll attach two .JPEG files for a few of you, and if anyone > wants them, just send me an e-mail at gcurve2000@..... > > If you look at the plots, I would recommend an idiot sender of 3 > to 5 psi. Once my bike was warmed up on a 70 degree day, it had > about 8 psi of oil pressure at 1,000 rpm and 16 psi at 4,000 rpm > (and a pretty straight line in-between). The oil was about 180-190F > measured at that same port. > > On a really hot day (105-110F) I rode more aggressively and the > oil was 230F. At 1,000 rpm, oil pressure was 5-6 psi. > > Thus the recommendation of 3-5 psi. I would suggest we're looking > for a total failure of the system (like a pump failure or failure of > the right crank end seal). Since these bikes run 5-70 psi all the > time depending on conditions, having a light trigger any higher will > have you staring at a red light every day after the bike warms up. > > As for location, agreed it's the most vulnerable. Depends on how > aggressive you are off road and how strong your skidplate is and how > far it must deflect to even contact an installed sensor. If you > install it on the banjo bolt, tell us what fittings you used to make > it happen. And although I agree with Mark B about the lowest > pressure location being the right exhaust cam bearing, that it would > take some machine work to actually get a probe in there, plus I > think we're just looking for "total failure" since that location is > clearly equal to or lower than the pressure's I've already measured, > and they're quite low. > > Bill Watson > Phoenix > > writes: > > KLRistas, > > > > Has anyone done the KLR oil light mod. By this I mean using the > > blank > > idiot light location. > > > > Any online pics or How-tos? > > > > I plan on adding an oil pressure gauge over the winter, but I am > > curious > > about this mod. > > > > Thane > > London, Ontario > >>>>>>>>>>>> >>>>>>>>>>>> > Thane, > > I haven't heard of anyone doing that yet. A few times I've heard > of > folks requesting info about it and talking about where to hook up a > sending unit. I seem to recall someone considering putting a > sending > unit at a banjo fitting on the right side of the bike. But I'm not > > sure. > I just took a look in the factory service manual and for > 2002-2003 models it suggests the oil pressure should be 11-21 psi @ > > 4,000 > rpm @ 194 degrees F. It doesn't say where that measurement is > taken. > > The wiring should be pretty easy as I think all you'll have to do > is > supply positive voltage to the light bulb and have negative voltage > go > to > the sending unit. > > > --------------------------------- > Yahoo! FareChase - Search multiple travel sites in one click. > > [Non-text portions of this message have been removed] > > > > Archive Quicksearch at: > http://www.angelfire.com/ut/moab/klr650_data_search.html > List sponsored by Dual Sport News at: www.dualsportnews.com > List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > Member Map at: http://www.frappr.com/dsnklr650 > Yahoo! Groups Links > > > > > > > >

[Mike Peplinski]

Using the under engine location, is this a simple drill and tap operation? Why not use an actual pressure gauge rather than a light? I, for one, am constantly checking my gauges, but repeatedly ride with the yellow directional light flashing. I guess I shouldn't have taken that "senior driver training" course.

>From: Bill Watson >To: DSN_KLR650@yahoogroups.com >Subject: [DSN_KLR650] Re: Anyone Do The Oil Light Mod? >Date: Mon, 21 Nov 2005 20:52:15 -0800 (PST) > >Thane, Jeff and Mark, > > About 6 months ago, I was discussing this with Norm Keller - Norm wanted >to test via a banjo fitting but hasn't gotten around to it yet. However, I >have tested through the bottom port as Thane mentioned... Jeff, you're >right about the spec of oil pressure at 4000 rpm and 194F, but the manual >does show this very location on page 4-14 of the base manual as where to >test. > > I agree with Jeff, it would be a breeze to do in terms of wiring - a 12V >supply to the bulb, and the grounding wire to the pressure sender. The >question of what pressure to have the light come on.... well, I'll attach >two .JPEG files for a few of you, and if anyone wants them, just send me an >e-mail at gcurve2000@..... > > If you look at the plots, I would recommend an idiot sender of 3 to 5 >psi. Once my bike was warmed up on a 70 degree day, it had about 8 psi of >oil pressure at 1,000 rpm and 16 psi at 4,000 rpm (and a pretty straight >line in-between). The oil was about 180-190F measured at that same port. > > On a really hot day (105-110F) I rode more aggressively and the oil was >230F. At 1,000 rpm, oil pressure was 5-6 psi. > > Thus the recommendation of 3-5 psi. I would suggest we're looking for a >total failure of the system (like a pump failure or failure of the right >crank end seal). Since these bikes run 5-70 psi all the time depending on >conditions, having a light trigger any higher will have you staring at a >red light every day after the bike warms up. > > As for location, agreed it's the most vulnerable. Depends on how >aggressive you are off road and how strong your skidplate is and how far it >must deflect to even contact an installed sensor. If you install it on the >banjo bolt, tell us what fittings you used to make it happen. And although >I agree with Mark B about the lowest pressure location being the right >exhaust cam bearing, that it would take some machine work to actually get a >probe in there, plus I think we're just looking for "total failure" since >that location is clearly equal to or lower than the pressure's I've already >measured, and they're quite low. > > Bill Watson > Phoenix > > writes: > > KLRistas, > > > > Has anyone done the KLR oil light mod. By this I mean using the > > blank > > idiot light location. > > > > Any online pics or How-tos? > > > > I plan on adding an oil pressure gauge over the winter, but I am > > curious > > about this mod. > > > > Thane > > London, Ontario > >>>>>>>>>>>> >>>>>>>>>>>> >Thane, > >I haven't heard of anyone doing that yet. A few times I've heard of >folks requesting info about it and talking about where to hook up a >sending unit. I seem to recall someone considering putting a sending >unit at a banjo fitting on the right side of the bike. But I'm not >sure. >I just took a look in the factory service manual and for >2002-2003 models it suggests the oil pressure should be 11-21 psi @ >4,000 >rpm @ 194 degrees F. It doesn't say where that measurement is taken. > >The wiring should be pretty easy as I think all you'll have to do is >supply positive voltage to the light bulb and have negative voltage go >to >the sending unit. > > >--------------------------------- > Yahoo! FareChase - Search multiple travel sites in one click. > >[Non-text portions of this message have been removed] > > > >Archive Quicksearch at: >http://www.angelfire.com/ut/moab/klr650_data_search.html >List sponsored by Dual Sport News at: www.dualsportnews.com >List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html >Member Map at: http://www.frappr.com/dsnklr650 >Yahoo! Groups Links > > > > > >

[jokerloco9@aol.com]

Has anyone done any experimentation to see about shimming any oil pressure relief springs (if any) in an effort to increase oil pressure a few pounds? Jeff A20 -----Original Message----- From: Mike Peplinski To: gcurve2000@...; DSN_KLR650@yahoogroups.com Sent: Tue, 22 Nov 2005 08:38:18 -0600 Subject: RE: [DSN_KLR650] Re: Anyone Do The Oil Light Mod? Using the under engine location, is this a simple drill and tap operation? Why not use an actual pressure gauge rather than a light? I, for one, am constantly checking my gauges, but repeatedly ride with the yellow directional light flashing. I guess I shouldn't have taken that "senior driver training" course.

>From: Bill Watson >To: DSN_KLR650@yahoogroups.com >Subject: [DSN_KLR650] Re: Anyone Do The Oil Light Mod? >Date: Mon, 21 Nov 2005 20:52:15 -0800 (PST) > >Thane, Jeff and Mark, > > About 6 months ago, I was discussing this with Norm Keller - Norm wanted >to test via a banjo fitting but hasn't gotten around to it yet. However, I >have tested through the bottom port as Thane mentioned... Jeff, you're >right about the spec of oil pressure at 4000 rpm and 194F, but the manual >does show this very location on page 4-14 of the base manual as where to >test. > > I agree with Jeff, it would be a breeze to do in terms of wiring - a 12V >supply to the bulb, and the grounding wire to the pressure sender. The >question of what pressure to have the light come on.... well, I'll attach >two .JPEG files for a few of you, and if anyone wants them, just send me an >e-mail at gcurve2000@..... > > If you look at the plots, I would recommend an idiot sender of 3 to 5 >psi. Once my bike was warmed up on a 70 degree day, it had about 8 psi of >oil pressure at 1,000 rpm and 16 psi at 4,000 rpm (and a pretty straight >line in-between). The oil was about 180-190F measured at that same port. > > On a really hot day (105-110F) I rode more aggressively and the oil was >230F. At 1,000 rpm, oil pressure was 5-6 psi. > > Thus the recommendation of 3-5 psi. I would suggest we're looking for a >total failure of the system (like a pump failure or failure of the right >crank end seal). Since these bikes run 5-70 psi all the time depending on >conditions, having a light trigger any higher will have you staring at a >red light every day after the bike warms up. > > As for location, agreed it's the most vulnerable. Depends on how >aggressive you are off road and how strong your skidplate is and how far it >must deflect to even contact an installed sensor. If you install it on the >banjo bolt, tell us what fittings you used to make it happen. And although >I agree with Mark B about the lowest pressure location being the right >exhaust cam bearing, that it would take some machine work to actually get a >probe in there, plus I think we're just looking for "total failure" since >that location is clearly equal to or lower than the pressure's I've already >measured, and they're quite low. > > Bill Watson > Phoenix > > writes: > > KLRistas, > > > > Has anyone done the KLR oil light mod. By this I mean using the > > blank > > idiot light location. > > > > Any online pics or How-tos? > > > > I plan on adding an oil pressure gauge over the winter, but I am > > curious > > about this mod. > > > > Thane > > London, Ontario > >>>>>>>>>>>> >>>>>>>>>>>> >Thane, > >I haven't heard of anyone doing that yet. A few times I've heard of >folks requesting info about it and talking about where to hook up a >sending unit. I seem to recall someone considering putting a sending >unit at a banjo fitting on the right side of the bike. But I'm not >sure. >I just took a look in the factory service manual and for >2002-2003 models it suggests the oil pressure should be 11-21 psi @ >4,000 >rpm @ 194 degrees F. It doesn't say where that measurement is taken. > >The wiring should be pretty easy as I think all you'll have to do is >supply positive voltage to the light bulb and have negative voltage go >to >the sending unit. > > >--------------------------------- > Yahoo! FareChase - Search multiple travel sites in one click. > >[Non-text portions of this message have been removed] > > > >Archive Quicksearch at: >http://www.angelfire.com/ut/moab/klr650_data_search.html >List sponsored by Dual Sport News at: www.dualsportnews.com >List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html >Member Map at: http://www.frappr.com/dsnklr650 >Yahoo! Groups Links > > > > > >

Archive Quicksearch at: http://www.angelfire.com/ut/moab/klr650_data_search.html List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Member Map at: http://www.frappr.com/dsnklr650 Yahoo! Groups Links [Non-text portions of this message have been removed]