klr650 tech talk nklr canadian/u.s. relations

[KLR650@webtv.net]

Elden wrote me: ( for immediate release) I just talked to a guy in Canada planning a global trip on a KLR.650 which I think is the perfect bike for the job. We discussed valve adjustments and I recommended that the engine have at least two thousand miles: even better three thousand so as to let the valves settle. Once they have stopped moving set the valves as close to the max as possible ( 0.008" + 0 .010" ) since they always seem to close. Take one full set of shims along that are one size thinner,and I believe you can make the whole globe. Avi Fishali and his three Israeli pals made it all the way from San Diego to the tip of South America, but called me from Mexico City and ordered 10 shims for 4 new bikes. House of Motorcycles shipped them direct by air. Avi thanked me for demanding that they learn KLR valve adjustment and insisting they make checks. The moral: Don't take a brand new KLR on a long trip until it's broken in well. Check the valves at Zero miles + set them to the max. Check them at 500, 1500, 2000 and if they are still moving, every 500 until they stop. Then set them above the middle (as close to max as possible) and go on your long trip. I set mine above the middle after break-in and then only check them every 10,000 miles. They've never been out of spec, and move very little on a heathy engine. I apologize but I somehow failed to nail down the Canadian riders name . ( Editors note: Just as well elden, this person is taking a semi-discreet approach and wishes to be anonymous at this stage , so listers let's please respect their wishes-CO.) Service notes: 1) It appears that Kawasaki -may have- finally eliminated the goofy pins and springs in the balancer sprockets of the KLR650. I beat them to it with help from Honda, Scott Wexman and Mike Cowlishaw. I've ordered a set (kawi) of new ones to study them and I'll report later. The tip off came from info from Canada. Mike Cowlishaw (619) 479-0123 now has the drive washers in stock which is the cheapest way to go if you have a pre-1996 KLR 650. Mine have gone over 40,000 miles and looked great on inspection. 2) My 54,000 mile KLR650 ( now 101,000) and Conall O'Briens 90,000 mile KLR650 both had jammed cam chain tensioners. Upon disassembly, Conall's cam chain was so loose it would not have gone much longer before derailing. Post '96 KLR 650's have a tensioner with a different number so I've got one on order. I'm not sure the old ones jam during the early life of the chain which is another reason for changing cam and balancer chains every 30,000 miles. 3)If you install a late model clutch in an early model KLR650 engine don't forget to remove the kick idler gear and install the late model spacer/collar on the end of the counter shaft. When I finish tearing down Conall O'Brien's 90,000 mile KLR650 engine and inspect all the components with the help of Vey de la Cruz I'll report the findings. In closing I'd like to reiterate that I believe the post 1996 KLR650's to be the best long distance motorcycle. The most important reason is the chain drive. With a brand new set of JT steel sprockets and an ERV II DID chain distributed through Southern Motorcycle Supply you'll go a long way. Put an extra set of sprockets and chain in the bottom of your panniers and you're set. Eric Siraton of Precision Concepts told me that the winning Honda in the Baja 2,000 ran the whole race on one ERV 2 chain. The same was true with the 2nd place Honda which Precision Concepts preped for Bruce Ogilvie and crew. BTW both chains were still in good shape at the end of the grueling race. The aluminum sprockets were changed with each of the five tire changes or the results might have been different. As you know aluminum is light, but not as tough as steel. I would never take a shaft drive bike on a long tough trip because they are more prone to breakage, and don't allow for good rear suspension due to excessive unsprung weight. Remember in the Paris to Dakar they had ace mechanics making repairs every night. I don't think a shaft drive has ever finished the Baja 1000. end of Elden's article. Plenty more of this good info in the Dual Sport News back issues. If you can at all possibly afford it, you owe it to yourself to get them. Conall A7,A9 KLR650

[Bogdan Swider]

> end of Elden's article. > > Plenty more of this good info in the Dual Sport News back issues. If you > can at all possibly afford it, you owe it to yourself to get them. > > Conall > A7,A9 KLR650 > >

Conall, I'm not one to question Papal edicts; you know my admiration for Elden but.............Are you guys totally sure about this post 95 solid balancer sprocket thing? Rich, Aussie in Vancouver, Kickbush checked part numbers a while back and pre, post 95 are the same. I know, he's in Canada which has some of the markings of a 3rd world country: devalued colorful funny money, ethnic groups threatening secession, socialism etc. I should check here at the home base of the world's only super power but today's Monday. Bogdan

[steve pye]

-----Original Message----- From: Bogdan Swider To: DSN_klr650@yahoogroups.com Date: Monday, April 16, 2001 1:18 PM

> Conall, I'm not one to question Papal edicts; Kickbush checked part >numbers a while back and pre, post 95 are the same. I know, he's in Canada >which has some of the markings of a 3rd world country: devalued colorful >funny money, ethnic groups threatening secession, socialism etc. I should >check here at the home base of the world's only super power but today's >Monday. Bogdan

Hey Bogdan, I'm going out on a limb here, is it possible Kawi changed the part and used the same number? I thought I saw a post a while ago that made reference to some of the pieces of the counter balancer upgrade using old numbers on new pieces. Maybe i'm way off, only way to check is to find a dealer with parts in stock and see what they got. I'd be happy to check for you but my socialist, 3rd world Kawi dealer won't carry any parts!!! Cheers, Steve

[Bogdan Swider]

> I'd be happy to check for you but my socialist, 3rd world Kawi dealer > won't > carry any parts!!! > > Cheers, > Steve > >

Lucky for me he was able to access the cam and balancer chains and thus with your kind help I was able to save a bunch of loonies even with paying that socialist VAT. Bogdan, whose still yearning to again pig out on a picnic table in front of an Ontario chip truck. Poutine anyone ?

[Swede]

Agh,agh,agh! See what happens when capitalism doesn't reign supreme, next thing you know, they'll be asking us to ship cheap parts to them. Oh...wait, does Dualstar ship to Canada? Hey Pye, I'll trade you a 5 gallon / flush toilet for anything you need for the KLR that's cheaper here. "Swede"

--- In DSN_klr650@y..., "Steve Pye" wrote: > I'd be happy to check for you but my socialist, 3rd world Kawi dealer won't > carry any parts!!! > > Cheers, > Steve