headlight bright at idle....dim when engine revs!!

[Tim & Missy]

Well, I finally got my flywheel off after getting my puller in the mail (thanks Fred!), I ended up using an air gun to get it off. Any way I originally thought my Balancer shaft broke but, that wasn't the case after all, (thank you KLR god) All that happened was the circlip on the end of the balancer shaft (left side) came off allowing the balancer weight and idler sprocket to slide off the shaft. After careful inspection the only damage I found was that the left coupling grinded up the springs in the idler sprocket. Also I don't know if this related or not but the back of the flywheel had some grating on the little 2 little riveted plates that are behind there, it looked like it was possibly from the cam chain but the chain appears to be alright not having any signs of damage. My questions to the group are: 1. I'm not sure what caused the circlip to come off but how could I get that to stay in there better in the future? Could I possible take a dremal or something and cut the grove just a tad deeper? the lip in the end of the shaft that holds the circlip in is a little worn but I would like to avoid replacing the whole shaft (and the associated work that goes with it) just for that. I'm definitely going to replace the circlip to start with. 2. Does anyone know the function of those little plates on the back of the flywheel sprocket? Since they were grated and loose I pulled them off, I can't see what there function is, if any. Thanks for any input. Timan

[Ron]

--- In DSN_klr650@egroups.com, Tim & Missy wrote:

> 1. I'm not sure what caused the circlip to come off but how could

I get that

> to stay in there better in the future? Could I possible take a

dremal or

> something and cut the grove just a tad deeper?

Those circlips are stamped out like cookies when they are made leaving a sharp edge on one side and a rounded edge on the other. They should always be installed with the sharp edge toward the outside of the shaft so that the gear or whatever they are holding on is not pressing the clip toward the rounded side. Ron

[pzzldpnthr]

I want to replace the front balancer shaft. I've taken the weights off both ends so that there is only the shaft and bearings. It seems I need to remove the bearings to get the shaft out. Is this right and if so how do you remove the bearings?

[Zachariah Mully]

pzzldpnthr wrote:

> I want to replace the front balancer shaft. I've taken the weights > off both ends so that there is only the shaft and bearings. It seems > I need to remove the bearings to get the shaft out. Is this right and > if so how do you remove the bearings?

IIRC, you need to split the cases to get the front shaft out. Z

[pzzldpnthr]

--- In DSN_KLR650@yahoogroups.com, Zachariah Mully wrote:

> > pzzldpnthr wrote: > > I want to replace the front balancer shaft. I've taken the

weights

> > off both ends so that there is only the shaft and bearings. It

seems

> > I need to remove the bearings to get the shaft out. Is this right

and

> > if so how do you remove the bearings? > > IIRC, you need to split the cases to get the front shaft out. > > Z >

I was afraid you'd say that.

[Gary]

That sucks out loud.

--- In DSN_KLR650@yahoogroups.com, Zachariah Mully wrote: > > pzzldpnthr wrote: > > I want to replace the front balancer shaft. I've taken the weights > > off both ends so that there is only the shaft and bearings. It seems > > I need to remove the bearings to get the shaft out. Is this right and > > if so how do you remove the bearings? > > IIRC, you need to split the cases to get the front shaft out. > > Z >

[John thomas]

if it is the left cover that is the generator cover. might hav jarred something loose? or damaged the windings or something under there.... however I would check the simple things first like the grounds (as in Kurts reply) it might also be simple to check the gen setup without removing the cover by checking the resistances ect as per manual at the plugs out side the cover. was that confusing? hope not to much lol. gl Kurt Grife wrote: --- In DSN_KLR650@yahoogroups.com, "rdougjenson" wrote:

> > Dropped my bike last night..and beside a miniscule hole for oil to

leak

> out of the side cover I thought everything was OK. But, once I

started

> driving, the light would go dim on me. Does not look like major

damage

> to the side cover, but there's obviously a problem. Any ideas? >

I had the same symptom when I had a bad ground connection, in my case it was the ground wire connector near the battery negative terminal. Kurt Thomas 90 Tengai 17,350 Forest Park Ga. --------------------------------- Get the Yahoo! toolbar and be alerted to new email wherever you're surfing. [Non-text portions of this message have been removed]