amendment: antigravity micro-start xp-1

James W. Flower · Post by **James W. Flower** » Sun Oct 26, 2014 11:08 pm

Yep, an American quarter is about 2mm thick, and the spec is 2-3mm, at the hand lever. The dimension I'm talking about is the amount of travel down below at the release lever, the one that's attached to the shaft that enters the case and pulls the clutch rod so the disks separate.tx- JW On Oct 26, 2014, at 7:02 PM, John Biccum wrote:

The factory specifies [i]so much[/i] movement as measured at the [i]end[/i] of the lever. ( Sorry for the imprecision , I m currently traveling without a KLR manual) But it s hard to make that measurement at the [i]end[/i] of the lever. I ve found that a $0.25 piece (a quarter) makes a great adjustment gage if the measurement is made between the lever and the end of the clutch perch housing. You should have about a quarter s worth of freeplay before clutch engagement. A precision clutch adjustment gage for $0.25, delivered, is somehow apropos of the frugality of the humble KLR.[b]From:[/b] DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] [b]Sent:[/b] Sunday, October 26, 2014 8:04 PM [b]To:[/b] DSN_KLR650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Re: Clutch lever play: How much is too much? This is weird: the bike definitely flunked this "drag test" (for lack of a better name) with the extra play. But that was new. The drag was so severe that I can't believe I've been riding with it like this and not noticed. And, when I adjusted it to spec (lower adjustment in the middle, 2-3 mm at the pivot), it dragged just as badly. I double-checked the adjustment. I'd already lubed the cable and checked for routing and fraying. I took it off and compared it to a new Motion Pro one, could see no difference. I installed the new one, which didn't help.
The distance the cable pulls the release lever is 11mm (measured where the cable attaches to the release lever). That seems plenty to separate the disks. With the cable disconnected I tried to work the release lever by hand, hoping to see if its total travel was more than 11mm: the springs are too strong for me to do that. I'm at the end of my expertise (not a long trip).-JW

jwflower53 · Post by **jwflower53** » Sun Oct 26, 2014 11:13 pm

Thanks Jeff, that worked. I undid the cable and used a big crescent wrench to turn the release lever. So now I know that the total possible travel, measured at where the cable attaches to the release lever, is about 22mm. I don't know where that gets me though, because the clutch worked fine for thousands of miles with the 11mm or so that the cable can pull it. The shop did nothing to the clutch except adjust it to spec (2-3mm at the hand lever).

-JWF

jwflower53 · Post by **jwflower53** » Fri Oct 31, 2014 1:09 am

Well Mike, you were right. The shop used Lucas oil. I changed back to Rotella T6 and the drag is noticeably less. It still seems like a lot, though I admit I never did this test before. It may have always been this way and always been fine. I'll keep an eye on it.

Btw, after draining the oil from a warm engine, leaning it back and forth as far as I could 5-6 times, giving it ten minutes to finish draining, and replacing the filter, it took 2100ml of T6 to reach a cold read level just under the Full mark on the glass with the bike upright. With the bike on its kickstand and the bars at left lock, there's just a teensie crescent showing at the bottom of the glass. Now I know... .

Jeff Saline · Post by **Jeff Saline** » Fri Oct 31, 2014 8:04 am

#ygrps-yiv-1961321575 .ygrps-yiv-1961321575ygrp-photo-title { TEXT-ALIGN:center;WIDTH:75px;HEIGHT:15px;CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575ygrp-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-1961321575 DIV.ygrps-yiv-1961321575photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575attach-table DIV.ygrps-yiv-1961321575attach-row { CLEAR:both;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575attach-table DIV.ygrps-yiv-1961321575attach-row DIV { FLOAT:left;} #ygrps-yiv-1961321575 P { PADDING-BOTTOM:3px;PADDING-LEFT:0px;PADDING-RIGHT:0px;CLEAR:both;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575ygrp-file { WIDTH:30px;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575attach-table DIV.ygrps-yiv-1961321575attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575attach-table DIV.ygrps-yiv-1961321575attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-1961321575 DIV.ygrps-yiv-1961321575ygrp-file-title { FONT-WEIGHT:bold;} #ygrps-yiv-1961321575 #ygrps-yiv-1961321575ygrp-mkp { BORDER-BOTTOM:#d8d8d8 1px solid;BORDER-LEFT:#d8d8d8 1px solid;PADDING-BOTTOM:0px;MARGIN:10px 0px;PADDING-LEFT:10px;PADDING-RIGHT:10px;FONT-FAMILY:Arial;BORDER-TOP:#d8d8d8 1px solid;BORDER-RIGHT:#d8d8d8 1px solid;PADDING-TOP:0px;} #ygrps-yiv-1961321575 #ygrps-yiv-1961321575ygrp-mkp HR { BORDER-BOTTOM:#d8d8d8 1px solid;BORDER-LEFT:#d8d8d8 1px solid;BORDER-TOP:#d8d8d8 1px solid;BORDER-RIGHT:#d8d8d8 1px solid;} #ygrps-yiv-1961321575 #ygrps-yiv-1961321575ygrp-mkp #ygrps-yiv-1961321575hd { LINE-HEIGHT:122%;MARGIN:10px 0px;COLOR:#628c2a;FONT-SIZE:85%;FONT-WEIGHT:700;} #ygrps-yiv-1961321575 #ygrps-yiv-1961321575ygrp-mkp #ygrps-yiv-1961321575ads { MARGIN-BOTTOM:10px;} #ygrps-yiv-1961321575 #ygrps-yiv-1961321575ygrp-mkp .ygrps-yiv-1961321575ad { PADDING-BOTTOM:0px;PADDING-LEFT:0px;PADDING-RIGHT:0px;PADDING-TOP:0px;} #ygrps-yiv-1961321575 #ygrps-yiv-1961321575ygrp-mkp .ygrps-yiv-1961321575ad P { MARGIN:0px;} #ygrps-yiv-1961321575 #ygrps-yiv-1961321575ygrp-mkp .ygrps-yiv-1961321575ad A { COLOR:#0000ff;TEXT-DECORATION:none;} On 30 Oct 2014 23:09:01 -0700 "jwflower53@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com> writes: Btw, after draining the oil from a warm engine, leaning it back and forth as far as I could 5-6 times, giving it ten minutes to finish draining, and replacing the filter, it took 2100ml of T6 to reach a cold read level just under the Full mark on the glass with the bike upright. With the bike on its kickstand and the bars at left lock, there's just a teensie crescent showing at the bottom of the glass. Now I know... . <><><><><><><> <><><><><><><> JW, Now you know that the mark on the engine is 400ccs shy of being full. Oil level in a KLR is important. Usually the first part(s) damaged from low oil level are the exhaust cam journal and cam journals in the head. Best, Jeff Saline The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . . . ____________________________________________________________ [b]Map Your Flood Risk[/b] Find Floodplan Maps, Facts, FAQs, Your Flood Risk Profile and More! floodsmart.gov

Norm Keller · Post by **Norm Keller** » Fri Oct 31, 2014 1:04 pm

#ygrps-yiv-1452627496 blockquote.ygrps-yiv-1452627496cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-1452627496 blockquote.ygrps-yiv-1452627496cite2 {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;margin-top:3px;padding-top:0px;} #ygrps-yiv-1452627496 .ygrps-yiv-1452627496plain pre, #ygrps-yiv-1452627496 .ygrps-yiv-1452627496plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;} #ygrps-yiv-1452627496 a img {border:0px;}#ygrps-yiv-1452627496 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-1452627496 .ygrps-yiv-1452627496plain pre, #ygrps-yiv-1452627496 .ygrps-yiv-1452627496plain tt {font-family:Tahoma;font-size:12pt;} Was the crankshaft at top dead center or bottom dead center when you drained the oil? As Paul Westman pointed out, the crankshaft has a center oil passage which anyone who has had the clutch cover off will have noticed. The crankshaft fits into an oil seal in a pocked in the clutch side cover so that oil is conveyed from the pocket, through the crankshaft and exits by a radial passage pointing up when the crankshaft is at TDC (top dead center). With crank at TDC, the oil tends to remain in the radial passage, crankshaft axial passage and side cover oil pocket, etc. When crankshaft is rotated towards BDC, the oil drains out. The difference is a couple of ounces if memory serves but makes enough difference in oil level/fill quantity to make some of the more "retentive" types very upset.

Of course the best practice is to simply ignore the whole thing and fill sort of to the level. If one is monitoring some factor such as oil consumption by top up amount, one might consider the factors. There's nothing quite like noticing a "new" noise or effect to create paranoia. That's one reason I try to keep notes on some things noticed so that I can refer back to help with memory. I used to notice sounds in the outboard, when 100 miles from anywhere, that weren't evident near home.

Clutch drag, for example, can be referenced for future by rolling the bike down a specific grade, under known temperatures, starting at the same speed in the same gear. Engine off, pull in the clutch and notice the speed at the bottom. It's much like comparing bike performance by use of 3rd gear roll-on through the full engine RPM range- find a reference which can be conveniently duplicated works for me most of the time.

jwflower53 · Post by **jwflower53** » Sat Nov 01, 2014 4:32 am

Jeff and Norm, maybe that's where that other 400ml was hiding, in the passage in the crankshaft. Next change I'll take that into account, just of obsessive/compulsive giggles.-JW

mark ward · Post by **mark ward** » Sat Nov 01, 2014 7:38 am

2 things. 1st. that tiny bit, Don't take it for granted, there may be some caught on the lip of the glass, while the actual level is lower. 2nd. Extra trapped, OLD DIRTY oil? Every few changes, (AFTER a long draining) I like to Dump a warmed Quart (Liter to you "others" LOL) in to Flush / Rinse out some of the Dirty oil left in. And every 2-3 yrs (10+- changes) Change the oil THEN Change again after running just 5+- miles, for a good Washing / rinsing out. (ESPECIALLY the first change on a "New" to me item. Because I have know idea how often the last person did it. May not do much for it, but makes me feel better. "Peace of mind") On Saturday, November 1, 2014 5:32 AM, "jwflower53@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com> wrote:

Jeff and Norm, maybe that's where that other 400ml was hiding, in the passage in the crankshaft. 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jwflower53 · Post by **jwflower53** » Sun Nov 02, 2014 12:23 pm

Mark- 1st. Good point. With the bike standing straight up the level is perfect,just under the full line. But for future checks, I guess I can't count on just reading the level while it's on its kickstand.

2d. So, you put that warmed quart right through, with the drain plug out? It would be interesting to see how it looks after that.

I think I'll got buy another gallon of T6.

-JW

jwflower53 · Post by **jwflower53** » Sun Nov 02, 2014 12:31 pm

Jeff- Or, now I know there's 400ml of old oil in there, maybe in the crankshaft, per Norm's message #15. Or I didn't get the motor hot enough, or I didn't let it drain long enough, or or or...

-JW

mark ward · Post by **mark ward** » Sun Nov 02, 2014 2:04 pm

I like to, put the plug in (just a few threads needed) Pour in the warmed quart, and let it gather in the pan, so it helps drag (rinse) a bit more debris out as it "rushes" out. ( HA "rushs" big word for such a slow run. LOL) On Sunday, November 2, 2014 1:31 PM, "jwflower53@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com> wrote:

Jeff- Or, now I know there's 400ml of old oil in there, maybe in the crankshaft, per Norm's message #15. 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clutch lever play: how much is too much?

clutch lever play: how much is too much?

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clutch lever play: how much is too much?

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