extended warranty report

[Sonny Bulla]

I was riding my '02 KLR650 to the dealer for it's first (500mile) service and, about halfway though the 30 mile ride, I start hearing a noise emanating from the left side of the engine. After all the talk on this list about chain tensioner problems, I immediately suspected that to be the source as the noise sounded like a chain rattling but, it only did it at various rpms as if something was going into a harmonic vibration. I, slowly, proceed on to the dealership and had them listen to it. The mechanic said he thought it was coming from the starter area. I left it with them overnight so they could tear into it and the next day I was told they couldn't find anything visually wrong, but suspected a bearing surface somewhere behind the clutch that they took apart and cleaned. A test ride confirmed the noise was gone but after a 100 mile ride yesterday it had returned. The noise appears as I go though the gears at about 3K rpms and higher and sounds just like a chain rattling at a very high frequency. I checked the balancer chain tension (as per this lists instructions) then started it up while on the kickstand and reved it up with no noise until I stood the bike up straight, then it came back. So, I guess it's going back in my truck and to the mechanic again. Any ideas? Sonny

[klrrdr]

The bike runs fine and sounds fine under normal acceleration. But when hard on it in 4th or 5th like when trying to pass it makes noises like BB's in a soda can. Any thoughts?

[Zachariah Mully]

On Wed, 2007-05-23 at 17:49 +0000, klrrdr wrote:

> The bike runs fine and sounds fine under normal acceleration. But when > hard on it in 4th or 5th like when trying to pass it makes noises like > BB's in a soda can. Any thoughts?

Pinging. Try higher octane gas. Or gas without ethanol or MTBE additives. Z

[greasedog123]

Need Help- My 03 KLR650 with 39,000 miles has just begun making a strange noise from the engine. A growly noise which sounds like a bad bearing which is louder when first started up. Then if I go at about 2,000 rpm steady in 2nd gear I hear a faint metalic clicking- not valve tapping. I had the dohickey done at about 6,000 miles and took side cover off and it and the spring seemed fine. Timing and balancer chain seemed ok. Checked valve clearance an they are within specs. I change oil every 2,000 miles. Bike runs good and no other issues. It may be time to trade. Any advice?

[Jeff Saline]

Listers, When I bought my 2003 KLR650 in September of 2003 it was used with about 1,500 miles on it. I found it on eBay, located in Texas at a used bike dealer and the timing was just right for a trip I had planned to see Steve Rankin. To pick up the KLR it was going to take me about 1 mile out of my route through Dallas. I did some research and using www.buykawasaki.com I discovered this bike had an extended warranty. Calling my local dealer they said it went with the bike and if I bought it all I'd have to do is bring it to them if I ever wanted to use the extended warranty. No hassle and no worries. I made a deal with the seller and I don't think he had any clue the bike had the warranty. Now if we fast forward to a month ago the story continues. Most of you probably realize I do most of my own work on my equipment and the KLR is no exception. I've now got over 23,000 miles on the bike and some of it has been in some pretty rough country. Two years ago I went through the forks with a complete teardown, inspection, cleaning and servicing. Well, someone mentioned on this list the extended warranty included the rear shock. I was surprised as I figured that was an expendable. So I kept that info in mind but didn't ever act on it, until about 3 weeks ago. I stopped at the dealer and spoke with the service manager about my warranty and the rear shock performance. The bike was handling funny at legal speeds and the rear shock was the cause. I figured it was just plain worn out. It wasn't leaking and the preload adjuster still worked but the shock sure wasn't working. The service manager suggested I bring it in and he'd see if they could get it covered under warranty. When I stopped in a week later he checked the VIN in the system and said the warranty was expiring in about 3 weeks. I guess timing is everything. He said he'd try to take care of the situation. On Wednesday I got the call he had a new rear shock for me. I stopped there this morning and got it all taken care of. They also did the recall for the muffler mount bolts. I have to admit I would have never bought the extended warranty myself. But knowing it came with the bike sure paid off for me this month. I got great customer service and had a very pleasant experience with the dealer. I can only hope that others enjoy a similar experience if they ever need to use a warranty. 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

[greasedog123]

Need help-- Sent this out once before with no response. My 03 KLR with 39,000 miles suddenly sounded different when I cranked it up one morning. I ride it to work everyday about 14 miles round trip. I take good care of the bike and it has run perfect since new. It sounds like a bad bearing with a steady groaning and light knock. When I ran it there was no loss of power but just doesn't sound right. Definitely coming from inside the engine. I checked the clutch side and flywheel side for obvious loose things but everything looked ok. My cam chain is a little loose on the front side of the chain and I am not sure if it should have any slack since there is a spring powered tensioner. I also checked the valve clearance and they were within specs. The dealer wanted 3-400 bucks just to start so I decided to do the work myself. Any ideas?

[traderpro2003]

I'm not sure what the problem is/could be. Unless you have a good shop and know what you're doing...and have time, this is when I drop it off at the dealer. It sounds like you've checked the obvious but without tearing-down the engine yourself, I'm not sure there's much I (group) can suggest. You've done well with 39k miles and considering it's a machine, you shouldn't be so weary of a qualified/good-rep dealer from having a look. It's not uncommon for the bill to exceed $1k, but then again you don't have to do the work/deal with it. I had a local dealer rebuild my engine (my fault), so sometimes you have to pass the torch. Now if money is no option, I'd trade it in on a new one Good luck - Brian --- In DSN_KLR650@yahoogroups.com, "greasedog123" wrote:

> > Need help-- > Sent this out once before with no response. My 03 KLR with 39,000 > miles suddenly sounded different when I cranked it up one morning.

I

> ride it to work everyday about 14 miles round trip. I take good

care

> of the bike and it has run perfect since new. It sounds like a bad > bearing with a steady groaning and light knock. When I ran it

there

> was no loss of power but just doesn't sound right. Definitely

coming

> from inside the engine. I checked the clutch side and flywheel

side

> for obvious loose things but everything looked ok. My cam chain is

a

> little loose on the front side of the chain and I am not sure if it > should have any slack since there is a spring powered tensioner. I > also checked the valve clearance and they were within specs. The > dealer wanted 3-400 bucks just to start so I decided to do the work > myself. > Any ideas? >

[Jeff Saline]

On Sat, 24 Nov 2007 01:19:07 -0000 "greasedog123" writes:

> Need help-- > Sent this out once before with no response. My 03 KLR with 39,000 > miles suddenly sounded different when I cranked it up one morning. > I > ride it to work everyday about 14 miles round trip. I take good > care > of the bike and it has run perfect since new. It sounds like a bad > > bearing with a steady groaning and light knock. When I ran it there > > was no loss of power but just doesn't sound right. Definitely > coming > from inside the engine. I checked the clutch side and flywheel side > > for obvious loose things but everything looked ok. My cam chain is > a > little loose on the front side of the chain and I am not sure if it > > should have any slack since there is a spring powered tensioner. I > > also checked the valve clearance and they were within specs. The > dealer wanted 3-400 bucks just to start so I decided to do the work > > myself. > Any ideas?

<><><><><><><><> <><><><><><><><> greasedog123, No real ideas for you as the description could be just about anything. : ( But, the cam chain run on the front of the engine would normally be under tension as the crankgear would pull the chain tighter. The tensioner only keeps the chain tight on the "loose" side. If you were in the left side of the engine did you check the starter drivetrain? Have you ever cleaned the oil pick up screen? I suppose it could just be a rod bearing starting to go bad. I think other guys on this list have more experience with that than me. 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