norm, more 29mm valve shim users

[jeffsaline]

Anybody have the Arctic Cat choke nut part number handy? This is the nut that is a direct replacement for the stock Kawasaki part but much less expensive. I am not needing info on the Stead brass nut. Thanks, Jeff Saline The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . . . . ____________________________________________________________ Old School Yearbook Pics View Class Yearbooks Online Free. Search by School & Year. Look Now! http://thirdpartyoffers.juno.com/TGL3141/55ac81525e7ae15264fdst04vuc

[jeffsaline]

On Sun, 19 Jul 2015 23:03:41 -0600 "salinej1@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com> writes:

> Anybody have the Arctic Cat choke nut part number handy? > > This is the nut that is a direct replacement for the stock Kawasaki > part > but much less expensive. > > I am not needing info on the Stead brass nut. > > Thanks, > > Jeff Saline > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650

<><><><><><><> <><><><><><><> KLR Listers, My google fu was weak but I think I've got it fixed now. : ) Arctic Cat, Carb Choke Plastic Nut, 5507-025 Thanks, Jeff Saline The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . . . . . ____________________________________________________________ Old School Yearbook Pics View Class Yearbooks Online Free. Search by School & Year. Look Now! http://thirdpartyoffers.juno.com/TGL3141/55ac89ac651b59ac23edst01vuc

[Norm Keller]

I'll trade you the confirmed by many purchases number if you can explain to me why people call it a "nut". A nut has female threads and the choke cable fitting has only male threads..

Carb choke plastic nut- Arctic Cat 5507-025

[Norm Keller]

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Brake rubbers: http://www.ronayers.com P/N 43020-1098 ('95)

Yamaha equivalent for the brake master cylinder piston replacement, here are the specs: Yamaha 1FK-W0042-50 rear, and 3XP-W0041-00 front.

 

Frt Brake Master: 2006-2010 CBR1000RR, 2007-2010 CBR600RR (radial design)

Smaller bore master cylinder (approx 50% increase in hydraulic pressure 10mm bore versus stock 12 mm bore: Ninja 250. (http://www.ebay.com/itm/7-8-Front-Right ... vxp=mtr>)

 

Braided brake hoses (need to identify length required) http://www.dhgate.com/product/1500mm-mo ... > Rear Brake Clevis: Zeta ZE89-5114

Front Caliper: from an SV650 Suzuki with the addition of a custom bracket.

Gen2 front rotor (280mm) to Gen1 with adapter bracket to accommodate stock front caliper relocation.

 

http://www.technafitstore.com/KAWASAKI- ... 807.htm> Rear rotor fits Gen1 & Gen2

[u]Filters[/u]

 

Oil filter- Wix 24951, NAPA 4951, Fram CH6070, P7027, K&N KN-123,

 

[u]Electrical[/u]

Tail Light Bulb- 2357 (stock 1034 or 1157)

 

Headlight Bulb- BP1210 80/110 watt

Licence plate bulb-

 

===============================================================

R/R: Mosfet FH012AA FH010AA from numerous bikes Mosfet Wire Adaptors: www.easternbeaver.com - also Triumph Part No. T2500676, link lead ===============================================================

FAN AND STARTER SAFETY CIRCUIT RELAY relay is rated 12Volts 22 Amps. Toyota part number 90987-02004-83 NAPA/Beck-Arnley P/N's BA203-0055/203-0055. Denso 056700-5260 Santech W0133-1635858 Autozone part number 19829 for $17 O'Reilly Auto Parts MPI 2JR6 $13 Carquest 56-1692 for 90-00 Lexus, 86-90 Acura, 03-82 Mitsubishi $24.14

[u]Wiring Harness Plugs[/u]

 

Gen2 http://cycleterminal.com/>  

 

 

[u]Engine  Parts[/u]

Stock drain plug- 12mm x 1.5mm

Low profile magnetic drain plug Can am part 420241782 (uses an Allen key)

 

Valve shims BMW 2000 F650, Ford SHO

Valve Shims: 29mm BMW K 75 ============================================================

 

Balancer shaft: 6004 (upper right side) and two 6204s (lower shaft, L&R). The fourth one (upper left side) "SX04A37" or updated to "TM-SX04A37" for long life material is Kawasaki OEM only.

 

The part numbers have changed Gen1 to Gen2, but I don't know if the sizes of the bearings have changed. If not, the bearing numbers for the Gen2's might be improved.

 

 

 

Shift shaft seal Kawasaki # 92050-082

O.D. 25 mm I.D. 13 mm Depth 7 mm

[u]Frame [/u]

[u] [/u]

Any jeep/4x4 shock boot will fit the front forks . skyjacker , rugged trail , rancho etc.

Fork Seals Gen1: Honda 91255-KA3-701

 

Suzuki foot peg part numbers:

 

Wide pegs: (Ron Ayers) 43550-14D30 and 43560-14D30. Springs- 09448-15008

Other pegs: 43550-44B10-019 and 43560-44B10-019. Springs 09448-15007 & 09448-15008.

MX Footpegs: 05 YZ250 OEM or Aftermarket with springs (small mod with file to fit) MX Footpegs: CRF50 pegs DR650 bolt on

 

Eagle Mike sells a higher strength frame bolt kit for the Gen1 KLR650. Price is about $25.00 including two high quality drill bits which are only required for the first installation. In case you prefer to source some locally, here are the contents & sizes:

Drill bits: 5/16", 13/32"

(2) 5/16" hardened flat washers 0.690" OD. Must be hardened washers or may squeeze out.

(2) Allen head cap screws 8 MM x 30 mm (1.25mm pitch). Head OD 12.85 mm could be a bit bigger so long as fit the holes in the sub-frame. High strength 12.8 grade

(1) Allen head 10 x 140 mm (1.5mm pitch)

(1) Hex nut 10 x 1.5mm pitch) self locking

 

-------------------------------------------------------------------------------------------------------------------------

Gen2 frame bolts

Lower frame: (2) Allen head cap screws 8 MM x 30 mm (1.25mm pitch). Head OD 12.85 mm could be a bit bigger so long as fit the holes in the sub-frame. High strength 12.8 grade

Upper frame: (2) Allen head cap screws 10 MM x 30 mm (1.25mm pitch). Head OD ?? mm could be a bit bigger so long as fit the holes in the sub-frame. High strength 12.8 grade

 

The rear suspension requires the following Koyo bearings or equivalent: Swing arm: 4x BM 2026 needle bearings (KHI 92046-1110), 6x MHA 20 27 5.7F seals (KHI 92049-1109) Pivot linkage: 2x BM 2817 large needle bearings (KHI 92046-1111), 2x BM 2026 needle bearings (KHI 92046-1110), 1x BM 2015 needle bearing (KHI 92046-1112), 2x MHA 28 34 5.7F large seals (KHI 92049-1181), 4x MHA 20 27 5.7F seals (KHI 92049-1109) If you consider the Moose Racing swing arm bearing kit, beware: It only contains the bearings, seals and shafts for the main pivot, not for the linkage connection.  Chinese bearings are supplied, and for $5 more, you can order the OEM Japanese bearings from Ron Ayers or such.  

 

 

 

[u] [/u]

====================================================================

[u]Tires & Wheels[/u]

Speedometer drive (wheel) seal 42x55x7.5

Front wheel bearing , Right side #6203[b][u] [/u][/b]Front wheel bearing, Left side #6202 Rear wheel bearing, Rt side #6204 Rear wheel bearing, Lt side #6003 Sprocket carrier bearing, #6004

Front Sprockets: 2001 660 yamaha raptors 14 through 11 tooth sprockets klx 650 13 tooth counter sprocket . Prevailing Rear Axle nut GenI: Honda 90305-KE8-003 Gen1 rear wheel complete with spacers will fit Gen2.

Tires:

Stock front:     Tube: 90/90 x 21 (

Stock rear 5.10 x 17  (130 x 17)

 

[u]Forks[/u]

 

Fork Seals GenI: Honda 91255-KA3-701

++++++++++++++++++++++++++++++++++++++++++++++++++++++

 

[u]Swing Arm & rear suspension[/u]

 

Rear swing arm assembly complete will swap between bikes. Needs caliper, rotor, adjusters, axle.

 

 

[u]Fuel System[/u]

Carb choke plastic nut- Arctic Cat 5507-025

MX Style Choke Plunger: Kawi# 16016-1068 From KLX250 and 300

Yamaha Raptor 660 petcock to replace KLT vacuum petcock with straight manual

Petcock Rebuild Kit: K&L supply 18-2723

Petcock knob O ring 92055-1085 Kawasaki industry standard ring #  "-019"

Petcock ring on diphragm 92055-1664 Kawasaki  industry standard size "-007" Float Valve: K&L Supply 18-8977 Air Cut Off Valve: K&L Supply 18-2799 CVK40 Slide Diaphragm: Harley Davidson 27585-88 float bowl o-ring: Harley Davidson #27577-88

 

Kawi KLX 650 P/N's  16009-1794 : KLX650 Needle-NITB 92037-1401 : Circlip 92143-1667 : Spacer 92063-1016 : 142 Main Jet 92063-1013 : 140 Main Jet 16017-1254 : Needle Jet 92064-1108 : 40 Pilot Jet 92064-1050 : 38 Pilot Jet

 

=============================================================================

[u]Cooling System[/u]

Thermostat OD 32 mm with rubber 1.260

 

 

Stock 160 F (72C) Linhaai Aeolus 260/300/400 Scooter http://www.ebay.ca/itm/231118932151?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

 

180 F Sega 250 Scooter Langley Sega distributor $42.00

195F (90C) from China

============================================================

Cooling fan EX500 fan motor & fan blades fit. Shroud does not fit and motor is smaller so best to use EX500 fan blade assembly on KLR motor.

==============================================================

 

Radiator cap:

cap is 13 psi rated 49085-1066    Kawasaki replacment ($30.00????) RR-27         Prestone  ($8) 10227         Stant T-13R         Motrad 1-227B        TVS 31333         Gates 7513          CST 703-4773      Balkamp

 

Goodyear #63936  (Re Big Cee) coolant hoses can be cut from. *Doesn t look useful*

 

Coolant hoses:

Changed the coolant hoses on KLR#2 today. The lower rad hose had a lovely display of green beads on the ends of the reinforcement braids around the end of the hose. Pretty!

 

In case this is helpful to someone:

 

Three hoses which are all 3/4" inside diameter.

 

1) Water pump to cylinder uses a relatively straight hose with 90 degree bend at the water pump end. Goodyear #65009 works perfectly with a bit trimmed from each end.

 

2) Lower radiator hose to water pump uses a relatively straight length of 3/4" ID hose. Ordinary 3/4" heater hose does the job well.

 

3) Upper radiator hose to thermostat housing. 3/4" heater hose which requires internal support to prevent kinking of the hose, or molded hose to fit. Could not identify hose in stock and the equivalent to the Goodyear #63936 was not available. NB* the #63936 appears to be a longer version of the Goodyear #65009 so don't see that it would be particularly satisfactory, given only one tight bend. Haven't had one in hand, however.

 

What worked well is an old trick which is to slip a coil spring into the hose which prevents the hose's kinking over while not significantly affecting coolant flow. I slipped a pair of Dynaline #24856 3/4x .091 - 6 inch long springs (two per package) into the length of straight heater hose and all is well.

 

Hoses $18.91 including taxes + springs $8.38.

 

 

[u]Clutch[/u]

Clutch cable Motion Pro  306-5029, Yamaha 5X6-26341-00 old YZ250?

V-Strom 650 clutch cable will also fit Gen1 & Gen2 cables will fit both bikes.

 

Hydraulic clutch kit: Ebay http://www.ebay.com/itm/381037574403?_t ... > ==================================================================

[jeffsaline]

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[Randy Jackson]

On 7/20/2015 8:57 AM, 'Norm Keller' normkel32@... [DSN_KLR650] wrote:

Here's a list of aftermarket parts which I have either discovered or been provided. Any additions/corrections would be appreciated. [b][u]Engine Parts[/u][/b]

Valve shims BMW 2000 F650, Ford SHO Valve Shims: 29mm BMW K 75 ============================================================

Norm, on BMW, make that Late K 750's, early ones used 19mm. Other Kawasakis that use 29mm shims: KL600s, KLX650's C & R, KZ900/1000/1100/1300 Yamaha XS400/750/850/1100 XJ550/650/700/900/1100 FJ600, FZ600, YX600 Later, Randy