fuel coming out of my 06 vent hose.

[Norm Keller]

#ygrps-yiv-1320887075 blockquote.ygrps-yiv-1320887075cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-1320887075 blockquote.ygrps-yiv-1320887075cite2 {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-1320887075 .ygrps-yiv-1320887075plain pre, #ygrps-yiv-1320887075 .ygrps-yiv-1320887075plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;white-space:pre-wrap;} #ygrps-yiv-1320887075 a img {border:0px;}#ygrps-yiv-1320887075 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-1320887075 .ygrps-yiv-1320887075plain pre, #ygrps-yiv-1320887075 .ygrps-yiv-1320887075plain tt {font-family:Tahoma;font-size:12pt;} Here's a link to my photos and information for the hydraulic clutch modification:   https://www.dropbox.com/sh/b6typ8ue8ueiz6d/AACuhJw9R3QmmA0-mAZbE0S0a?dl=0   The effort to pull the clutch lever to just about touching the grip is about 8-1/2 pounds. I forgot to measure the stock effort to hold the lever in that position so hope that someone with well lubricated lever can do a comparison. Gen1 & Gen2 may be different because I think Gen2 has larger pivot area and maybe different lever ratio?   I will prune the photos as many aren't useful. Thoughts?

[Martin Earl]

In the Oh-by-the-way department.A Gen2 clutch cable works on a Gen 1 bike; = gen 1 can use a gen 2 cable. Usure if the Gen to can use a Gen 1 Cable;the significant difference, the Gen 1 has a solid housing that takes the cable ~38.2degrees away from the clutch perch.I suspect it will work if necessary. I found the OEM Gen2 cable to be an upgrade from the OEM Gen 1.So, I guess it is a farkle on my ol'98.

On Thu, May 21, 2015 at 5:05 PM, 'Norm Keller' normkel32@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: Here's a link to my photos and information for the hydraulic clutch modification: https://www.dropbox.com/sh/b6typ8ue8ueiz6d/AACuhJw9R3QmmA0-mAZbE0S0a?dl=0 The effort to pull the clutch lever to just about touching the grip is about 8-1/2 pounds. I forgot to measure the stock effort to hold the lever in that position so hope that someone with well lubricated lever can do a comparison. Gen1 & Gen2 may be different because I think Gen2 has larger pivot area and maybe different lever ratio? I will prune the photos as many aren't useful. Thoughts?

[Norm Keller]

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 on KLRs with good success, IMO, because it is larger in diameter which apparently reduces drag.       ------ Original Message ------ From: "Martin Earl" To: "DSN KLR650" DSN_KLR650@yahoogroups.com>; "Norm Keller" Sent: 2015-05-21 4:30:39 PM Subject: Re: [DSN_KLR650] Hydraulic clutch modification completed  

In the Oh-by-the-way department. A Gen2 clutch cable works on a Gen 1 bike; = gen 1 can use a gen 2 cable.  Usure if the Gen to can use a Gen 1 Cable; the significant difference, the Gen 1 has a solid housing that takes the cable ~38.2degrees away from the clutch perch. I suspect it will work if necessary. I  found the OEM Gen2 cable to be an upgrade from the OEM Gen 1. So, I guess it is a farkle on my ol'98. On Thu, May 21, 2015 at 5:05 PM, 'Norm Keller' normkel32@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: Here's a link to my photos and information for the hydraulic clutch modification:   https://www.dropbox.com/sh/b6typ8ue8ueiz6d/AACuhJw9R3QmmA0-mAZbE0S0a?dl=0   The effort to pull the clutch lever to just about touching the grip is about 8-1/2 pounds. I forgot to measure the stock effort to hold the lever in that position so hope that someone with well lubricated lever can do a comparison. Gen1 & Gen2 may be different because I think Gen2 has larger pivot area and maybe different lever ratio?   I will prune the photos as many aren't useful. Thoughts?

[Michael Martin]

Norm, Imeasured 14 pounds on my Gen1 which has a newly-installed Kawasaki brand cable.  The scale's ontact point on the clutch lever was about a half inch (13 mm.) from the ball at the lever's end. Your photos would not display for me. Mike Martin   [b]From:[/b] "'Norm Keller' normkel32@... [DSN_KLR650]"    The effort to pull the clutch lever to just about touching the grip is about 8-1/2 pounds. I forgot to measure the stock effort to hold the lever in that position so hope that someone with well lubricated lever can do a comparison. 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[mrriley6311]

You may have a bad vacume diaphragm in the petcock. I had very similar problems last year with my 97 KLR, and thought it was a float or needle and seat problem. It was the diaphragm.

Sent from Samsung tablet.

[Norm Keller]

Thanks for the measurement Michael Martin. No idea why the photos won't display but if you send an email, I will forward a photo directly to test. If that works, I'm happy to send that way in order to hear your impressions.

[Michael Martin]

I tried again today and was able to access the photos. Anyhow, as expected since you came up with this,  the installation looks tidy. Do you think exhaust heat might affect the slave cylinder?  I can't judge the clearance from the photos. I wonder why the supplier recommends DOT3 fluid while the master cylinder cover says DOT4. Again, nice job, Norm.  Seems like a nice reduction in lever effort. Mike [b]From:[/b] "'Norm Keller' normkel32@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com>   Thanks for the measurement Michael Martin. No idea why the photos won't display but if you send an email, I will forward a photo directly to test. 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[Eddie]

#ygrps-yiv-498391620 {margin:0.7em;}#ygrps-yiv-498391620 p {margin:0;}#ygrps-yiv-498391620 .ygrps-yiv-498391620OECFntDef {font-family:"Segoe UI", Tahoma, Verdana, Arial, Helvetica, sans-serif;font-size:10pt;} Go with the DOT 4.   --- New Outlook Express and Windows Live Mail replacement - get it here: http://www.oeclassic.com/  It has a higher boiling point, won't hurt anything in a DOT 3 system and will mix fine with 3, too. -eddie     Original Message:

From: Michael Martin mmartin36@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> Reply-To: DSN_KLR650@yahoogroups.com>, Michael Martin To: DSN_KLR650@yahoogroups.com DSN_KLR650@yahoogroups.com> Sent: 5/23/2015 3:34:10 PM Subject: [DSN_KLR650] Re: Hydraulic clutch modification completed    I tried again today and was able to access the photos. Anyhow, as expected since you came up with this,  the installation looks tidy. Do you think exhaust heat might affect the slave cylinder?  I can't judge the clearance from the photos. I wonder why the supplier recommends DOT3 fluid while the master cylinder cover says DOT4. Again, nice job, Norm.  Seems like a nice reduction in lever effort. Mike [b]From:[/b] "'Norm Keller' normkel32@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com>   Thanks for the measurement Michael Martin. No idea why the photos won't display but if you send an email, I will forward a photo directly to test. If that works, I'm happy to send that way in order to hear your impressions.

[Norm Keller]

#ygrps-yiv-964076753 blockquote.ygrps-yiv-964076753cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-964076753 blockquote.ygrps-yiv-964076753cite2 {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-964076753 .ygrps-yiv-964076753plain pre, #ygrps-yiv-964076753 .ygrps-yiv-964076753plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;white-space:pre-wrap;} #ygrps-yiv-964076753 a img {border:0px;}#ygrps-yiv-964076753 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-964076753 .ygrps-yiv-964076753plain pre, #ygrps-yiv-964076753 .ygrps-yiv-964076753plain tt {font-family:Tahoma;font-size:12pt;} Time will tell regarding heat and the slave cylinder. I have exhaust wrap on the Gen2 header pipe + one might notice the metal shield tie wrapped to the coolant hoses. I've not known of any issue there but an experiment to see if I can measure elevated temperature on the plate when the weather becomes hot. I was interested in the brake fluid recommendations and not necessarily trusting to what was molded into the lid of a master cylinder which could be applied to many applications. As some will be aware, some hydraulic clutch systems recommend use of a mineral oil rather than brake fluid. Various "rubbers" can be very picky about the fluids to which they are exposed, especially where movement is involved. According to what I have read and brake schools which I have attended (automotive), the DOT 3 & 4 can be mixed without ill effects other than changes to boiling point. In addition, it appears that DOT 4 is thicker that DOT 3 but since this seems not particularly evident in use, I doubt the effects in motorcycle applications. I doubt that boiling point is an issue in either case when regarding this clutch application since I expect other problems before that temperature range. Since clutch action is most affected by fluid viscosity during release, I am concerned not to introduce a fluid of markedly greater viscosity since I do, at times, use the bike at near freezing temperatures and cannot determine the compensating port size. IME, excessive brake fluid viscosity has only been affective below zero F but all of these questions/potentials serve to challenge what one thinks that one knows. I do have a second slave cylinder which I purchased with great insight and for highly justifiable reasons.....OK, I didn't see the complete systems for sale for $39.00 and planned to find a master and hose separately.....why is it that the truth always makes me appear so much less than I wish?   If the slave does cook, I can swap in the other one so can try another option. Maybe I will pull the slave and cook it in a toaster oven while connected to see if that has any effects? Hoping someone has played with a KTM of such having a similar piston type slave.