08 KLR Clutch-Starter Troubleshooting #ygrps-yiv-2120009227 .ygrps-yiv-2120009227ygrp-photo-title { TEXT-ALIGN:center;WIDTH:75px;HEIGHT:15px;CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227ygrp-photo { BORDER-BOTTOM:black 1px solid;BORDER-LEFT:black 1px solid;BACKGROUND-COLOR:white;WIDTH:62px;BACKGROUND-REPEAT:no-repeat;BACKGROUND-POSITION:center 50%;HEIGHT:62px;BORDER-TOP:black 1px solid;BORDER-RIGHT:black 1px solid;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row { CLEAR:both;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row DIV { FLOAT:left;} #ygrps-yiv-2120009227 P { PADDING-BOTTOM:3px;PADDING-LEFT:0px;PADDING-RIGHT:0px;CLEAR:both;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227ygrp-file { WIDTH:30px;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227attach-table DIV.ygrps-yiv-2120009227attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-2120009227 DIV.ygrps-yiv-2120009227ygrp-file-title { FONT-WEIGHT:bold;} From: "Scott Marlow" To: DSN_KLR650@yahoogroups.com> Date: Wed, 4 Sep 2013 08:18:10 -0700 Subject: [DSN_KLR650] 08 KLR Clutch-Starter Troubleshooting Message-ID: This past December, my local Kawasaki shop had to repair the clutch-starter on my 2008 KLR (~25,000 miles). Symptoms On bike startup intermittently - but frequently - I was hearing a very loud 'K-thunk' - as if the bike was starting/'catching' in gear (but it was always in Neutral). Problem An approx. ~1/8" "part of the secondary reduction gears case had been broken". (I WISH I had taken a picture). Repair This involved draining the case; replacing the generator case cover, 2 gaskets, shaft idler, and some washers and bearings ($285 + labor). The problem disappeared until a couple weeks ago when it resurfaced L The dealer has offered to open the clutch case to inspect and promise to "make it and treat me right." The shop had never seen or heard of such an issue, and they could not determine what caused the problem. In fact, they had to find some parts on eBay because it was so difficult to procure them. I'm concerned why this issue has sprung up again. Any ideas? Could this be some type of 'lemon' issue? Maybe something in the clutch-starter that was missed and also needed to be replaced? Some foreign object in the oil? Sorry, I can't be more specific - but this type of issue is way above my meager mechanical skills. Obviously, I don't want to keep pouring repair $$ into a 5-year old KLR with 28k miles. Any tips appreciated. Scott Marlow
(206) 784-5454 <><><><><><> <><><><><><> Scott, I think you have what is known as the deep hole issue. As I understand it, some 08s, and maybe a few early 09s, had the hole for the starter reduction gear shaft in the left outer cover machined too deep. It allows the shaft to slip to the left and then get out of alignment. I think it's a warranty issue and should be addressed at no cost to you. But you should allow your dealer to work that with you. It sounds like you have a good relation with the dealer and that is more than half the battle in getting warranty issues settled. The fix I have heard is to put a ball bearing or piece of rubber hose/tube into the hole to prevent the shaft from slipping into it further than the designers wanted. You can probably learn more at
www.klr650.net using the search function for deep hole. I apologize now if it takes you to something inappropriate. I think EagleMike has been including the ball bearing in doohickey kits for the 08s. Hope this is correct and helpful. Best,
Jeff Saline
The Beautiful Black Hills of South Dakota
75 R90/6, 03 KLR650
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