bikes gone, now time for the parts to go

[Fred Hink]

Do you have a magnetic drain plug? Sounds like one would pay off with broken springs and missing washers. It s better to find these pieces before your transmission does. There are dots painted on your counter balancer chain for timing the crank to the counter balancer shafts. If your chain tensioner has jumped time, that is no problem since it isn t timed to anything. Jumping time with the crank or counter balancer shafts is much harder and I doubt they have changed. You will need a service manual to see where those painted dots are supposed to line up if you want to check the timing of the crank and counter balancer shafts. Fred http://www.arrowheadmotorsports.com From: RobertWichert Sent: Monday, August 19, 2013 5:38 PM To: Jeff Saline Cc: DSN_klr650@yahoogroups.com Subject: Re: [DSN_KLR650] Doohickey Story - Long Update... The spring was, and is, definitely broken. The crankcase hook end is MIA. The spring itself shows some signs of abuse (Dented a bit. Prolly got caught by the chain or something.). I will try to find the hook end. I also need to look for one thrust washer which appears to have gotten away from me. Fishing expedition starts tomorrow. This is probably just for curiosity, but how do you index/time the balancer(s)? Is there a mark or something? It appears that I can remove the tensioning sprocket. As a matter of fact, the insides of the tensioning sprocket fell out on their own. I haven't moved anything, but I'd like to know that the timing of the balancer(s) is right, so if there is a way to do that, and you know what it is, kindly help me out. Any other hints or ideas are welcome. Bottom line - Bad spring. No cookie. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 8/17/2013 10:16 AM, RobertWichert wrote: > > 25,000 miles. Time for a chaing. > > Robert P. Wichert P.Eng. LEED AP BD&C > +1 916 966 9060 > FAX +1 916 966 9068 > > On Aug 17, 2013, at 9:46 AM, Jeff Saline > wrote: > > > On Sat, 17 Aug 2013 09:02:04 -0700 RobertWichert > > > writes: > >> I'm pretty sure I've been running it like this though. I noticed > >> more > >> vibes than usual and I was wondering so I took it apart. > >> > >> How strong is that spring, anyway? I kind of feel resistance, but > >> it > >> may just be the chain. > >> > >> Would a broken spring cause more vibes than usual? > >> > >> > >> Robert Wichert P.Eng. LEED AP BD&C > >> +1 916 966 9060 > >> FAX +1 916 966 9068 > > <><><><><><> > > <><><><><><> > > > > Robert, > > > > The spring puts a pretty good tension on the doohickey. When you get to > > the chain there will be no more movement. > > > > A broken spring by itself probably won't cause more vibration. What > > usually happens is the spring is broken because that's what happens with > > KLRs. Then instead of fixing this common issue early in the bike's life > > the owner thinks it won't happen to them. The spring breaks and there is > > absolutely no indication in most cases. In a few cases part of the > > broken spring gets into an important part and destroys the lower end of > > the engine. In rare cases it locks the engine and causes an accident. > > Finally the owner decides they should do some maintenance and > loosens the > > adjuster lock bolt about a turn. Since there is no spring tension, any > > tension that was on the chain is relieved. This is a slack chain and can > > put the balancer shafts out of time just a tad. The owner tightens the > > adjuster lock bolt to 69-71 inch pounds and thinks all is fine. What > > they really did was loosen the chain and cause a problem. They may > > notice more vibration but since they still feel lucky they attribute it > > to the KLR being a large thumper or something else. > > > > On the Gen I KLRs the springs are known to break more than the > doohickeys > > but there are problems with both. On the Gen II KLRs the springs often > > are no longer providing tension by 1,500 miles and for sure you are > lucky > > if at 5,000 miles there is any tension at all with the stock spring. The > > Gen II doohickeys are redesigned and much stronger than the previous > > version but the hole is often a bit larger (0.005" or so) and > doesn't fit > > on the shaft quite as well as it should/could. The fix is the same > in all > > cases and cost is pretty reasonable compared to the cost of damage that > > could be caused by not taking care of this issue. > > > > 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 > > > > . > > . > > . > > . > > . > > > > __________________________________________________________ > > One Weird Trick > > Could add $1,000s to Your Social Security Checks! See if you Qualify... > > http://thirdpartyoffers.juno.com/TGL3141/520fa8b0ba08328b041c6st03vuc > > > > [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[montequint]

Stock seat All tools and gaskets for doohicky upgrade, (spring style) (rotor bolt, wrench, etc) Just looking for a fair price but they do need to go. Contact me off-list at monteruwei@... or 503-668-3627

[RobertWichert]

Thanks Fred... I have manuals so I'll check that out. And I'm going fishing tomorrow! Cheers! Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 8/19/2013 4:49 PM, Fred Hink wrote: > Do you have a magnetic drain plug? Sounds like one would pay off with > broken springs and missing washers. It s better to find these pieces > before your transmission does. > There are dots painted on your counter balancer chain for timing the > crank to the counter balancer shafts. If your chain tensioner has > jumped time, that is no problem since it isn t timed to anything. > Jumping time with the crank or counter balancer shafts is much harder > and I doubt they have changed. You will need a service manual to see > where those painted dots are supposed to line up if you want to check > the timing of the crank and counter balancer shafts. > Fred > http://www.arrowheadmotorsports.com > > *From:* RobertWichert > *Sent:* Monday, August 19, 2013 5:38 PM > *To:* Jeff Saline > *Cc:* DSN_klr650@yahoogroups.com DSN_klr650@yahoogroups.com> > *Subject:* Re: [DSN_KLR650] Doohickey Story - Long > > Update... > > The spring was, and is, definitely broken. The crankcase hook end is > MIA. The spring itself shows some signs of abuse (Dented a bit. Prolly > got caught by the chain or something.). > > I will try to find the hook end. > > I also need to look for one thrust washer which appears to have gotten > away from me. Fishing expedition starts tomorrow. > > This is probably just for curiosity, but how do you index/time the > balancer(s)? Is there a mark or something? It appears that I can > remove the tensioning sprocket. As a matter of fact, the insides of the > tensioning sprocket fell out on their own. I haven't moved anything, > but I'd like to know that the timing of the balancer(s) is right, so if > there is a way to do that, and you know what it is, kindly help me out. > > Any other hints or ideas are welcome. > > Bottom line - Bad spring. No cookie. > > Robert Wichert P.Eng. LEED AP BD&C > +1 916 966 9060 > FAX +1 916 966 9068 > > =============================================== > > On 8/17/2013 10:16 AM, RobertWichert wrote: > > > > 25,000 miles. Time for a chaing. > > > > Robert P. Wichert P.Eng. LEED AP BD&C > > +1 916 966 9060 > > FAX +1 916 966 9068 > > > > On Aug 17, 2013, at 9:46 AM, Jeff Saline > > wrote: > > > > > On Sat, 17 Aug 2013 09:02:04 -0700 RobertWichert > > > > > > writes: > > >> I'm pretty sure I've been running it like this though. I noticed > > >> more > > >> vibes than usual and I was wondering so I took it apart. > > >> > > >> How strong is that spring, anyway? I kind of feel resistance, but > > >> it > > >> may just be the chain. > > >> > > >> Would a broken spring cause more vibes than usual? > > >> > > >> > > >> Robert Wichert P.Eng. LEED AP BD&C > > >> +1 916 966 9060 > > >> FAX +1 916 966 9068 > > > <><><><><><> > > > <><><><><><> > > > > > > Robert, > > > > > > The spring puts a pretty good tension on the doohickey. When you > get to > > > the chain there will be no more movement. > > > > > > A broken spring by itself probably won't cause more vibration. What > > > usually happens is the spring is broken because that's what > happens with > > > KLRs. Then instead of fixing this common issue early in the bike's > life > > > the owner thinks it won't happen to them. The spring breaks and > there is > > > absolutely no indication in most cases. In a few cases part of the > > > broken spring gets into an important part and destroys the lower > end of > > > the engine. In rare cases it locks the engine and causes an accident. > > > Finally the owner decides they should do some maintenance and > > loosens the > > > adjuster lock bolt about a turn. Since there is no spring tension, any > > > tension that was on the chain is relieved. This is a slack chain > and can > > > put the balancer shafts out of time just a tad. The owner tightens the > > > adjuster lock bolt to 69-71 inch pounds and thinks all is fine. What > > > they really did was loosen the chain and cause a problem. They may > > > notice more vibration but since they still feel lucky they > attribute it > > > to the KLR being a large thumper or something else. > > > > > > On the Gen I KLRs the springs are known to break more than the > > doohickeys > > > but there are problems with both. On the Gen II KLRs the springs often > > > are no longer providing tension by 1,500 miles and for sure you are > > lucky > > > if at 5,000 miles there is any tension at all with the stock > spring. The > > > Gen II doohickeys are redesigned and much stronger than the previous > > > version but the hole is often a bit larger (0.005" or so) and > > doesn't fit > > > on the shaft quite as well as it should/could. The fix is the same > > in all > > > cases and cost is pretty reasonable compared to the cost of damage > that > > > could be caused by not taking care of this issue. > > > > > > 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 > > > > > > . > > > . > > > . > > > . > > > . > > > > > > __________________________________________________________ > > > One Weird Trick > > > Could add $1,000s to Your Social Security Checks! See if you > Qualify... > > > http://thirdpartyoffers.juno.com/TGL3141/520fa8b0ba08328b041c6st03vuc > > > > > > > > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]