countershaft interchangeability

[Chris Norloff]

Had a great ride at Hatfield-McCoy (Pinnacle Creek system) in West Virginia this last weekend. (http://trailsheaven.com) However, on the second day I started hearing a 'squawk' from the bike, a deep sound that makes me think it's in the frame. The sound typically came when the front wheel started going up the next slope and the rear wheel was still going down. So it looks like something big has loosened. Subframe maybe? I've got the through-bolt mod installed. Likely culprit? thanks, Chris P.S. The KLR is a bit big for some of those trails, but handled them all (just green and blue; didn't try the black trails). It was pretty impressive to get the bike pointed in the right direction, pull the trigger and hang on!

[Ed Dobson]

--- In DSN_KLR650@yahoogroups.com, "Chris Norloff" wrote:

> > Had a great ride at Hatfield-McCoy (Pinnacle Creek system) in West

Virginia

> this last weekend. (http://trailsheaven.com) > > However, on the second day I started hearing a 'squawk' from the bike, a > deep sound that makes me think it's in the frame. The sound

typically came

> when the front wheel started going up the next slope and the rear

wheel was

> still going down. So it looks like something big has loosened. Subframe > maybe? I've got the through-bolt mod installed. > > Likely culprit? > > thanks, > Chris > > P.S. The KLR is a bit big for some of those trails, but handled them all > (just green and blue; didn't try the black trails). It was pretty

impressive

> to get the bike pointed in the right direction, pull the trigger and

hang

> on!

SWAG. Might you have the dreaded frame backbone crack? ED

[nickyandscrappy]

In 1990 the length of the countershaft/transmission output shaft splines were lengthened. Does anyone know if the pre-90 and post-90 countershafts could be interchanged? I have an 88 that has a shaft with worn splines and the sprocket is slipping. I tried to order a replacement and found out that Kawasaki has stopped production of them and is out of inventory. Of course, since this is a rarely serviced part, of the 25 or so, shops that I've contacted, nobody has one. So, I was wondering if I could buy one of the newer shafts, which hopefully Kawasaki still has in inventory, and use it instead. I've got some inquiries going with some salvage yards for a used one, but I'd rather have new, since I'm going to the trouble of splitting the case. One good thing about tearing the engine apart,though, I found out that the piston had a crack in the sidewall and a big chunk broke off. But the doohickey is fine!?!? Over 12000 miles and it's still in one piece. I did order a replacement from Fred before having the engine torn down. Better to replace it now than later. Well, if anyone can give me an definite answer on the countershaft, it would be appreciated. I haven't ridden the bike since last August, and spring fever and high gas prices are really starting to get to me. Thanks, Tim