[dsn_klr650] improving your klr

[Bogdan Swider]

In heated agreement with Bogdan and his Albatross about checking the clutch while you have it tore down. Historically, the clutch is very robust; some have indicated it is an identical KHI application on a bike of greater HP as well. However, it will fail if you pile enough mud up in the swing arm before you clean it out! Yes, Rev My plates measured as new but my springs were borderline ..disgusting that they wore out so fast; the bike had only 70K miles at the time. I'll say it again .the springs are so easy to change and the cost is so minimal might as well do it while you're in the neighborhood. Kinda like changing the spark plug when you do a valve lash inspection. Bogdan [Non-text portions of this message have been removed]

[Jud]

The first "must do" I read about with this bike was to replace the stock shift lever, said to be prone to failure. So I bought an aftermarket lever and stuck it in a tank bag, figuring to install it soon, when the inevitable occurred. Well the inevitable has not yet happened, and the replacement lever still sits there in the tank bag, a testament to the power of karmic prophylaxis.

--- In DSN_KLR650@yahoogroups.com, "eddie" wrote: > > Fred's advice about the shifter is right-on-point. I looked down at my shifter by chance once and noticed that the stock shifter was cracked; and about to fail. I'd start there. BTW, I use my KLR as a daily rider and do no off road. So even with "normal" use, the shifter can fail. > > Eddie > > --- In DSN_KLR650@yahoogroups.com, "Fred Hink" wrote: > > > > Have you checked your shift lever to see if it might be cracked at the weld where you tighten to the shift shaft? Is this the stock OEM shift lever or aftermarket? I m betting OEM. > > > > Fred > > http://www.arrowheadmotorsports.com > > > > > > > > From: achesley43@ > > Sent: Wednesday, February 20, 2013 7:14 AM > > To: DSN_KLR650@yahoogroups.com > > Subject: [DSN_KLR650] Transmission Woes > > > > > > Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. > > > > > > > > > > > > [Non-text portions of this message have been removed] > > >

[Desert Datsuns]

Yep, that's how it works. If you carry a spare, you'll never need it......but as soon as you don't have it with you, it will break. On my CR250 I was breaking clutch and brake levers like crazy. So I bought 2 extra of each, and of course haven't needed either of them since. Just how it works. Ryan Phoenix, AZ Jud wrote:

> > > The first "must do" I read about with this bike was to replace the stock > shift lever, said to be prone to failure. So I bought an aftermarket > lever and stuck it in a tank bag, figuring to install it soon, when the > inevitable occurred. > > Well the inevitable has not yet happened, and the replacement lever > still sits there in the tank bag, a testament to the power of karmic > prophylaxis. > > --- In DSN_KLR650@yahoogroups.com , > "eddie" wrote: > > > > Fred's advice about the shifter is right-on-point. I looked down at > my shifter by chance once and noticed that the stock shifter was > cracked; and about to fail. I'd start there. BTW, I use my KLR as a > daily rider and do no off road. So even with "normal" use, the shifter > can fail. > > > > Eddie > > > > --- In DSN_KLR650@yahoogroups.com > , "Fred Hink" wrote: > > > > > > Have you checked your shift lever to see if it might be cracked at > the weld where you tighten to the shift shaft? Is this the stock OEM > shift lever or aftermarket? I m betting OEM. > > > > > > Fred > > > http://www.arrowheadmotorsports.com > > > > > > > > > > > > From: achesley43@ > > > Sent: Wednesday, February 20, 2013 7:14 AM > > > To: DSN_KLR650@yahoogroups.com > > > Subject: [DSN_KLR650] Transmission Woes > > > > > > > > > Well, after 31,950 miles and 13 years, I finally had a road > breakdown on the '00 KLR. Lucky was just getting into my buddies > driveway. Had shifted to 1st after he opened the gate and never could > get it to 2nd gear. We played with it and finally got it back to Nu. > Restarted bike , engaged 1st again and same, could not get into N or > 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, > I'll pull the clutch side and see if the problem is in that section. > > > > > > > > > > > > > > > > > > [Non-text portions of this message have been removed] > > > > > > > > > No virus found in this message. > Checked by AVG - www.avg.com http://www.avg.com> > Version: 2012.0.2238 / Virus Database: 2639/5619 - Release Date: 02/20/13 >

[Ian Francisco]

My 2000 (A14) got stuck in third gear one night on the way home. Actually the best gear of all of them to get stuck in. Low enough to take off with some clutch slip and capable of almost 50mph. Turned out to be the spring that keeps the pawl engaged with the shift drum. Easy to fix once the cover was removed. Care must be taken with the water pump impeller nut and the ceramic seals when disassembling. I had some pics of what's under the cover but be danged if I can find them Wed Feb 20, 2013 6:21 am (PST) . Posted by: "achesley43@..." achesley43@... Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. -- Ian Francisco http://www.scarletfuries.com http://www.facebook.com/pages/The-Scarlet-Furies/121218125931 [Non-text portions of this message have been removed]

[John Biccum]

Here is a link to hi-resolution pics, showing the spring Ian is describing. http://johnbiccum.smugmug.com/Motorcycles/KLR-Clutch/19095765_VwqsMT#!i=1486 017391 http://johnbiccum.smugmug.com/Motorcycles/KLR-Clutch/19095765_VwqsMT#!i=148 6017391&k=sBG5Sw7> &k=sBG5Sw7 For a sudden failure like Achesley is describing I'd first look at the shifter, as others have noted. But if that is OK, the spring that Ian mentioned (I call the "omega spring" in the pics) is also a good candidate. I'd buy a new clutch pack springs set before tearing into the clutch side as those springs are likely to be in need of replacement soon and it sure makes sense to replace them while you are in the clutch side. At 66K miles my clutch disks all measured fine and displayed no discoloration or other indications of trouble. In fact they measured almost the same as the new parts. But the clutch pack spring set was all at the low limit (free height) and the new springs were measurably taller and had noticeably greater spring tension. My clutch was just beginning to slip a bit under hard acceleration when I replaced the parts. From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of Ian Francisco Sent: Thursday, February 21, 2013 11:27 To: achesley43@...; DSN KLR650 Subject: [DSN_KLR650] re: transmission woes My 2000 (A14) got stuck in third gear one night on the way home. Actually the best gear of all of them to get stuck in. Low enough to take off with some clutch slip and capable of almost 50mph. Turned out to be the spring that keeps the pawl engaged with the shift drum. Easy to fix once the cover was removed. Care must be taken with the water pump impeller nut and the ceramic seals when disassembling. I had some pics of what's under the cover but be danged if I can find them Wed Feb 20, 2013 6:21 am (PST) . Posted by: "achesley43@... achesley43@... Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. -- Ian Francisco http://www.scarletfuries.com http://www.facebook.com/pages/The-Scarlet-Furies/121218125931 [Non-text portions of this message have been removed]

[Bogdan Swider]

Close to my experience with similar mileage. One difference being that my clutch was not yet beginning to slip. Bogdan From: John Biccum > Date: Thursday, February 21, 2013 1:50 PM To: 'Ian Francisco' >, "achesley43@..." >, 'DSN KLR650' DSN_KLR650@yahoogroups.comDSN_KLR650@yahoogroups.com>> Subject: RE: [DSN_KLR650] re: transmission woes Here is a link to hi-resolution pics, showing the spring Ian is describing. http://johnbiccum.smugmug.com/Motorcycles/KLR-Clutch/19095765_VwqsMT#!i=1486 017391 http://johnbiccum.smugmug.com/Motorcycles/KLR-Clutch/19095765_VwqsMT#!i=148 6017391&k=sBG5Sw7> &k=sBG5Sw7 For a sudden failure like Achesley is describing I'd first look at the shifter, as others have noted. But if that is OK, the spring that Ian mentioned (I call the "omega spring" in the pics) is also a good candidate. I'd buy a new clutch pack springs set before tearing into the clutch side as those springs are likely to be in need of replacement soon and it sure makes sense to replace them while you are in the clutch side. At 66K miles my clutch disks all measured fine and displayed no discoloration or other indications of trouble. In fact they measured almost the same as the new parts. But the clutch pack spring set was all at the low limit (free height) and the new springs were measurably taller and had noticeably greater spring tension. My clutch was just beginning to slip a bit under hard acceleration when I replaced the parts. From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of Ian Francisco Sent: Thursday, February 21, 2013 11:27 To: achesley43@...; DSN KLR650 Subject: [DSN_KLR650] re: transmission woes My 2000 (A14) got stuck in third gear one night on the way home. Actually the best gear of all of them to get stuck in. Low enough to take off with some clutch slip and capable of almost 50mph. Turned out to be the spring that keeps the pawl engaged with the shift drum. Easy to fix once the cover was removed. Care must be taken with the water pump impeller nut and the ceramic seals when disassembling. I had some pics of what's under the cover but be danged if I can find them Wed Feb 20, 2013 6:21 am (PST) . Posted by: "achesley43@... achesley43@... Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. -- Ian Francisco http://www.scarletfuries.com http://www.facebook.com/pages/The-Scarlet-Furies/121218125931 [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[achesley43@ymail.com]

Yes! Parts arrive last night via UPS. Now, for it to warm up and me put it all back together again. I don't too much go play in my shop when temp is under 60 degrees. Had to do that too much in my life earning a living on drilling rigs and platforms , now, I don't gotta.

[mark ward]

60?? AS IN 60F, Tshirt weather? Why I long for the 40f+ days of spring in Michigan. 60c is hide in the freezer untill global warming is over, time.

--- On Thu, 2/28/13, achesley43@... wrote: From: achesley43@... Subject: [DSN_KLR650] Transmission Woes To: DSN_KLR650@yahoogroups.com Date: Thursday, February 28, 2013, 2:13 PM Yes! Parts arrive last night via UPS. Now, for it to warm up and me put it all back together again. I don't too much go play in my shop when temp is under 60 degrees. Had to do that too much in my life earning a living on drilling rigs and platforms , now, I don't gotta. [Non-text portions of this message have been removed]

[Mike Huber]

Time to really rub it in !!!! Gonna be 80* on Sunday in Carlsbad NM !!!!! I'm Ridin' !!! Mike Huber To: DSN_KLR650@yahoogroups.com; achesley43@... From: nomad59@... Date: Thu, 28 Feb 2013 08:18:29 -0800 Subject: Re: [DSN_KLR650] Transmission Woes 60?? AS IN 60F, Tshirt weather? Why I long for the 40f+ days of spring in Michigan. 60c is hide in the freezer untill global warming is over, time.

--- On Thu, 2/28/13, achesley43@... achesley43@...> wrote: From: achesley43@... achesley43@...> Subject: [DSN_KLR650] Transmission Woes To: DSN_KLR650@yahoogroups.com Date: Thursday, February 28, 2013, 2:13 PM Yes! Parts arrive last night via UPS. Now, for it to warm up and me put it all back together again. I don't too much go play in my shop when temp is under 60 degrees. Had to do that too much in my life earning a living on drilling rigs and platforms , now, I don't gotta. [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[Ron Haraseth]

I'll vouch for the Ricors. Installed a set last winter in my main machine (2000), and have absolutely no regrets. They do reduce the brake dive and make small harsh bumps go away, plus handle the big ones. I'm past 260 dressed for war, and usually manage another 30-60 pounds of luggage and don't let any of that slow me down. Also installed a Ricor rear with a very heavy spring rate so the back keeps up with the front pretty well. So I have already invested my money, but of course I do have a second KLR (2002) which could use a set also...if the price was right... Ron -----Original Message----- From: eddie Sent: Saturday, March 02, 2013 7:58 AM To: KLR650 list Subject: Re: [DSN_KLR650] Improving your KLR I think Progressive makes a fork guts kit for the KLR, too. Fred? I wonder if a set of Honda XL600V pegs would fit a KLR? They had a rubber cover that was 1 10mm head bolt removable - exposing a nice, cleated off road peg. Need highway comfort? Put the covers on. Off road a lot? Leave 'em off. -eddie

----- Original Message ----- From: Lee Dodge To: KLR Group Sent: Saturday, March 02, 2013 9:41 AM Subject: [DSN_KLR650] Improvng your KLR Last night after reading the latest issue of Cycle World and the powerful recommendation the 5 testers gave the KLR ( See earlier posting), I gave Fred a call about the article and added a recommendation of an accessory that will /is transforming the suspension of the KLR damper rod ft. fork. That product is the Ricor inserts that literally transform the KLR fork into a Cartridge fork in terms is dynamic responses. This morning I had more ideas, (the morning after thing), as I remembered the only complaints the test4ers had of the KLR were "the rubber footpegs" and "the front suspension". all things considered thats pretty tame criticism and though quite constructive. Therein was the genesis of a proposal I'll describe as follows: If enough of us combine an order of the Ricor fork inserts (see links below) we could then negotiate with the manufacturer for a lower price than the already low price when considering what the product does. My thought was to collect commitments to buy to 1 point and then leverage that volume buy so 'the KLR community' or a significant proportion of it can improve your KLR. So where's the focal point to be? My next thought was . . How about Arrowhead? To me it was amazing that for $200 the testing riders at Cycle world would not have had even those 2 complaints, and many of us have already gotten the right foot pegs now we need to improve the suspension. YOUR THOUGHT? Lee [Non-text portions of this message have been removed] ------------------------------------ List Sponsors - Dual Sport News: http://www.dualsportnews.com Arrowhead Motorsports: http://www.arrowheadmotorsports.com List FAQ courtesy of Chris Krok: http://www.bigcee.com/klr650faq.html Members Map https://maps.google.com/maps/ms?msid=212558560286766214899.0004d0fa9f1732283bb6f&msa=0&ll=38.522384,-109.489746&spn=6.831383,9.624023Yahoo! Groups Links