--- In
DSN_KLR650@yahoogroups.com, "Al Cooper" wrote:
>
> I am preparing my 04 KLR for a trip down the GDT next summer and in
my
> reading of others adventures and read of several who have
experienced clutch
> failure on this ride. Is there a time when need to be replaced or
is the
> failures mentioned due to abuse. In other words, should I replace
my
> 20,000+ clutch as a precautionary move?
>
Al,
You are perhaps referring to my own experience last summer....
Jud has mentioned that a new one could be in as much trouble as a
used one...if presented the right conditions--which I completely
concur.
Bottom line first:
Unless your bike has issues now, it is not something that I would do
in advance.
And now to make the short answer much longer, cough.
John's bike blew the clutch out because the back tire loaded up with
gumbo, and he was desperate to pull through the bog, --he did not
realize he was not turning the tire as the engine was still reving.
ie slipping/burning up the clutch. Understand a sane person under
normal circumstances 'might' immediatelty recognize the problem. Now
think of having had as many as 6 bike drops in sticky gumbo during
the past 3 hours--you begin to see/experience the necessity of trying
to free yourself of this nightmare. I got through/out of the bog,
John limped out of the worst part of it before the bike gave up
the 'clutch-ghost'. We are now some 100 yds apart...and the wind is
picking up, I believe there were snow pellets and it is past nautical
twilight.
We set up our tents in the middle of this sticky mess (in the least
sticky place we could find) where every step had 1" of mud clinging
to your boot. It was a fitful night--yeah, it was a dark and stormy
night....
The next morning, we both had had to dig a huge load of gumbo, the
consistency of play-dough out of our drive train--remembering that
both of us have ridden through all the same stuff. My bike has some
27K miles on it, John' bike has ~7K as I recall. How much mud did we
accumulate? Easily 40# or more. I was using a K270, John was using
D606. The clay would stick to the tire and roll up like a ribbon,
load up the tire, and then trapping itself first at the swing arm,
against the shock and eventually against the chain and upward to the
inner fender. The mud was at least 4" deep inside the rim. John's
bike was much the same. When I finally cleared the life sucking mud
from the drive train (1.5-2 hours of digging) the seat of the pants,
pit in the middle of your stomach feelings suggested that my clutch
was not as strong as it was earlier that same day.
Cowboy rescue via 4x4 ford F150, 60 miles to Riverton, WY, we get to
see John's damaged clutch. I recall 5 of the metal spacers were
discolored, the whole mess 'stunk' of burning, and I think 3 of the
clutch disc's were without any clutch material. and The clutch
springs-- what clutch springs?
Ah,
Nothing VISA won't fix.
Most excellent service at Wild West Motorsports, Riverton, WY!
Based on what I saw, experienced as well, I took the 'high' road of
caution and ordered OEM clutch parts through Jeff Saline at the Rapid
City, Kawi dealer.
Fast forward to Rapid City, some 14 days later. I tore down the
clutch assembly (and cleaned the screen!) under the supervision of
Jeff Saline--having clutch plates and metal spacers on hand for a
complete replacement. Not one clutch plate failed 'spec' for
thickness or any metal spacer failed for warpage tolerance as
measured on a granite inspection plate. One plate was slightly
discolored (heated) and should have been replaced.
The interesting thing, was that the clutch spring were all .050 less
than the new springs. Did I do that? or was it normal wear and
tear? Of all the things 'necessary for replacement were the springs,
and one metal spacer for discoloration.
The high road suggested--hard use, soft-feeling clutch--it is all
torn down--install the new OEM parts. So we did.
There was a noticeable difference in having a new clutch, vs a 29K
mile clutch.
My other KLR has 25K on it. It will go on the GDR in two years from
now with my son--no mods to the clutch before we go--unless something
drastic happens between now and then.
Got to go--kids music concert in 10 minutes.
revmaaatin.