Probably no more so that for the doohickey - just the other side of the motor.> Jim, is a big deal getting to the oil screen? How much stuff has to be > taken off?
You do have to remove some of the water pump apparently. There are
good notes on Eldon Carl's site...
http://multisurfacemotorcycling.com/klrpage/oilscreen.htm
JimI have not had mine fail. But I have conducted or attended about five tech days, opened up maybe thirty or forty bikes, and seen a half dozen broken levers, and eight or ten broken springs. I have been to CMC in Moab a couple of times, and each time seen a broken lever replaced in the campground, and on each occasion heard at dinner about one or more failures uncovered at the tech session at Fred's shop. In five years, there have been at least four or five reports on this list or on klr650.net of catastrophic failures, not counting the Striking Vikings busted lever in Argentina. Often, all that holds the parts of the lever in place is the flange on the adjustment bolt. It is possible for a KLR to run for tens of thousands of miles with a broken lever, skirting disaster only by virtue of the owner's failure to do regular maintenance. Dealers don't find broken levers because they don't look for them.> > Okay, now I -know- this has been talked to death, so feel free to > ignore this post as it comes from a total KLR newbie and, frankly, may > even sound inflamatory to some (though I certainly don't mean it to be > that way). > > I'm just wondering about how many people have -actually- had the > doohickey fail. When I asked the guys at Rocky Mountain Kawasaki > about it, they referred me to the head mechanic there who told me that > he'd been working on Kawis since 1987 on a ton of KLRs that live in > the mountains most of their lives and had never seen one fail, _ever_, > from natural causes. He said he's seen a couple fail because someone > was working on it themselves and tightened down the bolt too tight and > split the piece apart, but that he honestly believed it was just an > urban myth that they break or are something to be concerned about. > > I'm curious: I know there are a lot of KLR guys on this list with a > lot of KLR experience. So tell me, is he just some weird statistical > anomaly that has never seen this part actually fail? How many on this > list have actually had the part fail on them in the field? >
There's a fair amount of history available on the factory parts. We've run at least 3 surveys I can remember on different forums. About 30 percent came back with broekn parts, when the left side was opened. This survey and history included bikes with less than 500 miles - no way the parts should be broken at that mileage. I've personally seen broken springs with less than 800 miles on the bike - 782 miles to be exact. I've personally seen broken levers with less than 1800 miles on the bike. I don't know when the parts actually broke - but they were broken when the engine was opened with that mileage. Most of the time the pieces stay in place, but not always. Sometimes the vibration gradually increases (and noise), and the bike being a single some of this is expected. Almost every person that does the upgrade experiences a smoother and quiter engine - even those that have intact parts in the engine. Sometimes the intact parts are not adjusting properly because the lever is embossed into the case. Some people think the lever breaks only due to ham-fisted mechanics. To this I ask - then why were the parts broken prior to adjustment, at such low mileage? Some people are lucky, and the parts never break. I do know for sure that the riders with high mile bikes would have a smoother engine if the lever and spring were replaced, especially with a proper length spring. Once in a great while there is catastrophic failure. I've spoken to the owners of a few of these bikes, and a dealer in the Toronto area (IIRC) that has rebuilt 2 engines due to balancer lever problems. Mark (FREEFLOW on ADV Rider) had a broken spring go through the cam chain and sprocket, causing altered valve/cam timing. He was lucky as the valves did not hit the piston. Biker Scout (KLRforum.com) had pieces of his lever lock up the engine when he fell over, fortunately without major engine damage, but there was minor engine damage. If you don't think you need to replace the lever and/or spring, then don't. It's entirely up to you, as it's your machine. Disclosure - I'm one of the guys making aftermarket parts for the balancer system. all the best, Mike Eagle Mfg & Eng> > I'd guess there are a few variables here: > > 1) how many actually take the KLR's in for service vs DIY > 2) how many people get a new KLR and immediately replace the doo? > > My KLR will never see a shop if I can help it, and with my recently > acquired 04 - I'm just going to go ahead and replace it - cheap > insurance. When I did my 98 (around 10k mi) - the doo and spring were > both fine - though at the time there was only one spring available and > in hindsight I probably could have used a shorter spring. > > The first time I did it was mainly to get comfortable tearing into the > motor... This time I'll probably do the doo and oil screen at the > same time - button it up and know I don't have to worry about anything > for awhile. > > Jim >
BTW, the KLR tech session thing sounds like a super cool idea. I wish
I knew someone around northern Colorado who was doing one!
Neil
On 10/18/06, Jud Jones wrote: > --- In DSN_KLR650@yahoogroups.com, "Neil Doane" wrote: > > > > Okay, now I -know- this has been talked to death, so feel free to > > ignore this post as it comes from a total KLR newbie and, frankly, may > > even sound inflamatory to some (though I certainly don't mean it to be > > that way). > > > > I'm just wondering about how many people have -actually- had the > > doohickey fail. When I asked the guys at Rocky Mountain Kawasaki > > about it, they referred me to the head mechanic there who told me that > > he'd been working on Kawis since 1987 on a ton of KLRs that live in > > the mountains most of their lives and had never seen one fail, _ever_, > > from natural causes. He said he's seen a couple fail because someone > > was working on it themselves and tightened down the bolt too tight and > > split the piece apart, but that he honestly believed it was just an > > urban myth that they break or are something to be concerned about. > > > > I'm curious: I know there are a lot of KLR guys on this list with a > > lot of KLR experience. So tell me, is he just some weird statistical > > anomaly that has never seen this part actually fail? How many on this > > list have actually had the part fail on them in the field? > > > > I have not had mine fail. But I have conducted or attended about five tech days, opened up > maybe thirty or forty bikes, and seen a half dozen broken levers, and eight or ten broken > springs. I have been to CMC in Moab a couple of times, and each time seen a broken lever > replaced in the campground, and on each occasion heard at dinner about one or more > failures uncovered at the tech session at Fred's shop. > > In five years, there have been at least four or five reports on this list or on klr650.net of > catastrophic failures, not counting the Striking Vikings busted lever in Argentina. > > Often, all that holds the parts of the lever in place is the flange on the adjustment bolt. It > is possible for a KLR to run for tens of thousands of miles with a broken lever, skirting > disaster only by virtue of the owner's failure to do regular maintenance. > > Dealers don't find broken levers because they don't look for them. > > > > > 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 > > > > >
--- In DSN_KLR650@yahoogroups.com, "Mike Hilton" wrote: > > "Oh, and its about $13K" > That translates into 2 and one half KLR's. Less money more fun and less maintenance.. > > Mike H. > > 2008 KLR 650 > http://groups.msn.com/08KLR650E8F/shoebox.msnw? action=ShowPhoto&PhotoID=6 > 2003 K1200GT > http://www.msnusers.com/2003K1200GT/shoebox.msnw? action=ShowPhoto&PhotoID=4 > Mike's 1978 R100S & "S" information > http://groups.msn.com/1978bmwr100sinformation/shoebox.msnw? action=showphoto&photoid=15 > Work URL, Ruston City Marshal > http://www.bayou.com/rustonmarshal/ > ----- Original Message ----- > From: freidawg > To: DSN_KLR650@yahoogroups.com > Sent: Sunday, October 19, 2008 7:00 PM > Subject: [DSN_KLR650] I rode the F800gs yesterday > > > > The local BMW place has 2 F800GS bikes. I went and rode their demo > bike yesterday. > > It weighs only a little bit more that the KLR, same riding position, > has tons more power at all RPMs. Awesome suspension, great brakes. > > I think it is *the* adventure tourer. > > Oh, and its about $13K.
install> > KLRers, > > In looking at a used KLR650, how do I tell if it's too late to
Larry, Good question! Long story short; does it start and run without any vicious noise or vibration? Probably, still good to go. Vibration; might be nice to have another KiLeRista along that has ridden one to compare what you are looking at with one that is AOK. revmaaatin.> a doohickey -- if the damage is already done?j > > Thanks, > Larry >
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