what i hate about the klr....................

[Norm Keller]

"I ve had to jump mind a couple of times. I use the frame for the negative and the bolt on the starter. J Make sure your key is on AND it s out of gear when you do it, because the starter will start turning immediately. GregM"

 

 

 

If you use the other starter relay connection, it connects to the battery and allows normal starting operation. Gen1 will start and run without battery power but Gen2 requires power.

[Norm Keller]

#ygrps-yiv-1466705159 blockquote.ygrps-yiv-1466705159cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-1466705159 blockquote.ygrps-yiv-1466705159cite2 {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-1466705159 .ygrps-yiv-1466705159plain pre, #ygrps-yiv-1466705159 .ygrps-yiv-1466705159plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;white-space:pre-wrap;} #ygrps-yiv-1466705159 a img {border:0px;}#ygrps-yiv-1466705159 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-1466705159 .ygrps-yiv-1466705159plain pre, #ygrps-yiv-1466705159 .ygrps-yiv-1466705159plain tt {font-family:Tahoma;font-size:12pt;} Here are some photos of the engine internals for a Gen2 which had the left rear idler shaft bearing fail. It's back on the road but thought the photos might be of interest/use to someone:   https://www.dropbox.com/sh/70l5l5mqptlumql/AAC0rah__d8MCVjLsD5g-ozMa?dl=0

[Mark Van Horn]

How many miles at the time of failure?

On Sat, Jun 27, 2015 at 3:30 PM, 'Norm Keller' normkel32@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: Here are some photos of the engine internals for a Gen2 which had the left rear idler shaft bearing fail. It's back on the road but thought the photos might be of interest/use to someone: https://www.dropbox.com/sh/70l5l5mqptlumql/AAC0rah__d8MCVjLsD5g-ozMa?dl=0

[Norm Keller]

#ygrps-yiv-122723116 blockquote.ygrps-yiv-122723116cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-122723116 blockquote.ygrps-yiv-122723116cite2 {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-122723116 .ygrps-yiv-122723116plain pre, #ygrps-yiv-122723116 .ygrps-yiv-122723116plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;white-space:pre-wrap;} #ygrps-yiv-122723116 a img {border:0px;}#ygrps-yiv-122723116 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-122723116 .ygrps-yiv-122723116plain pre, #ygrps-yiv-122723116 .ygrps-yiv-122723116plain tt {font-family:Tahoma;font-size:12pt;} I can't recall but guess around 35,000. It should be here in a while so will try to remember to check.   ------ Original Message ------ From: "Mark Van Horn" To: DSN_KLR650@yahoogroups.com; "Norm Keller" Sent: 2015-06-27 7:44:35 PM Subject: Re: [DSN_KLR650] Gen2 internal engine photos  

How many miles at the time of failure? On Sat, Jun 27, 2015 at 3:30 PM, 'Norm Keller' normkel32@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: Here are some photos of the engine internals for a Gen2 which had the left rear idler shaft bearing fail. It's back on the road but thought the photos might be of interest/use to someone:   https://www.dropbox.com/sh/70l5l5mqptlumql/AAC0rah__d8MCVjLsD5g-ozMa?dl=0

[Martin Earl]

Hi Norm,What do you attribute to the bearing falilure?Looking at the piston--Was this bike a 'known' burner prior to the bearing failure? Top of piston looks like an oil burner to me. Not as oily as my 57Kmile oil burner. grin. Did you do a 685 up grade at the time of this repair? What was the condition of the air cleaner?From the photo, Looks like a lot of dirt was getting by the air cleaner, according to what the spark plug is showing; or is the plug telling you something else?Were they using a K&N filter by chance? martinearl.

On Sat, Jun 27, 2015 at 1:30 PM, 'Norm Keller' normkel32@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: Here are some photos of the engine internals for a Gen2 which had the left rear idler shaft bearing fail. It's back on the road but thought the photos might be of interest/use to someone: https://www.dropbox.com/sh/70l5l5mqptlumql/AAC0rah__d8MCVjLsD5g-ozMa?dl=0

[Norm Keller]

#ygrps-yiv-2009900508 blockquote.ygrps-yiv-2009900508cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-2009900508 blockquote.ygrps-yiv-2009900508cite2 {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-2009900508 .ygrps-yiv-2009900508plain pre, #ygrps-yiv-2009900508 .ygrps-yiv-2009900508plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;white-space:pre-wrap;} #ygrps-yiv-2009900508 a img {border:0px;}#ygrps-yiv-2009900508 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-2009900508 .ygrps-yiv-2009900508plain pre, #ygrps-yiv-2009900508 .ygrps-yiv-2009900508plain tt {font-family:Tahoma;font-size:12pt;} It wasn't using an excessive amount of oil, even running at those high speeds and loads. Attributing the bearing failure is really a crap shoot but my time in heavy industry leads me to guess it was simply a bearing near the low end of the failure range. Bearing life can be calculated from the speed, load, lubrication and other factors, as most will know, but this gives the mean life. Bearings will fail along a wider range depending. Given the very low failure rate of this bearing, it's not likely, IMO, that this is a problem. This particular bearing has a special bearing using high life materials and, it memory serves, there have been two engineering changes by the bearing maker. I continue to mull over Paul Westmans thought that more oil flow may benefit this bearing so intend to modify the banjo bolts to both head and transmission if time allows while the bike is here, tomorrow. I have no idea as to how one might test this hypothesis since the failure rate is so tiny. The piston shows fairly typical oil carbon deposits: https://www.dropbox.com/sh/emmhzbzwe3r38a2/AACL9-NgMHSxgnDFh36ILFFva?dl=0 It does show fairly heavy carbon with the classic oil-coming-past-the-piston sign of a clean area around the periphery of the piston crown. One factor which needs be plugged in is that this engine was running at very fast highway speeds, and loaded to the gills (two up + more than 100 pounds of gear) for more than 8,000 miles. This will almost certainly provide a different oiling effect than the typical short haul KLR. The cylinder and piston weren't showing excessive wear so just cleaned, honed and new rings. Stock air filter and no signs of excessive dirt which isn't surprising given all pavement highway. Hard to diagnose from photos as they never look quite like the actual components, IME. ------ Original Message ------ From: "Martin Earl" To: "DSN KLR650" DSN_KLR650@yahoogroups.com>; "Norm Keller" Sent: 2015-06-28 8:04:06 PM Subject: Re: [DSN_KLR650] Gen2 internal engine photos  

Hi Norm, What do you attribute to the bearing falilure? Looking at the piston-- Was this bike a 'known' burner prior to the bearing failure?  Top of piston looks like an oil burner to me. Not as oily as my 57Kmile oil burner. grin.   Did you do a 685 up grade at the time of this repair? What was the condition of the air cleaner? From the photo, Looks like a lot of dirt was getting by the air cleaner, according to what the spark plug is showing; or is the plug telling you something else? Were they using a K&N filter by chance? martinearl. On Sat, Jun 27, 2015 at 1:30 PM, 'Norm Keller' normkel32@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote: Here are some photos of the engine internals for a Gen2 which had the left rear idler shaft bearing fail. It's back on the road but thought the photos might be of interest/use to someone:   https://www.dropbox.com/sh/70l5l5mqptlumql/AAC0rah__d8MCVjLsD5g-ozMa?dl=0