Wilsons Sandbox

John, I haven't been inside there.........hopefully someone who has will respond to you by tomorrow. Getting the right info is worth missing a day or two of riding. Meanwhile, may I remind you of what Mark Van Horn asked about the washer being in place? From you're response, it wasn't clear you'd checked that specific part. Do you have Mark's and Devon's pictures showing the parts placements? Do you have the exploded diagrams from the manual? Triple check the assemblies, and do so before torquing the rotor bolt, which may become (or already is?) damaged from re-use. Speaking of the rotor bolt, are you sure it or any other hardwear affecting the starter clutch hasn't become mis-aligned or cross-threaded? The answer is in there............. The Mule

----- Original Message ----- From: "mrdishpig" To: DSN_klr650@yahoogroups.com> Sent: Thursday, April 24, 2003 11:41 PM Subject: [DSN_klr650] RE: Help! rotor install problem > I changed my Doohickey that part went well. when i went to install > the rotor i torqued it and the starter clutch wont spin. > I took it back off tried it again 85 ft.lbs it spins 110 ftlbs it is > locked up. I tried it without the half moon key still the same > story. I am to the point i dont know what else to try. Anyone have > any insite ? thanks! John M > > > all the spacers seem to be in the correct location are all 650s > rotor bolt torqued to 130 ft lbs? > am i missing something? thanks John M > > > > > List sponsored by Dual Sport News at www.dualsportnews.com. List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > Unsubscribe by sending a blank message to: > DSN_klr650-unsubscribe@yahoogroups.com . > > > > Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/ > >

For what its worth, I did my doohicky 2 months ago and reused the rotor bolt and had no troubles at all. Yes torque on that bolt is 130 lbs. MrMoose A8 (Barbie and Ken special)

--- In DSN_klr650@yahoogroups.com, "mrdishpig" wrote: > I changed my Doohickey that part went well. when i went to install > the rotor i torqued it and the starter clutch wont spin. > I took it back off tried it again 85 ft.lbs it spins 110 ftlbs it is > locked up. I tried it without the half moon key still the same > story. I am to the point i dont know what else to try. Anyone have > any insite ? thanks! John M > > > all the spacers seem to be in the correct location are all 650s > rotor bolt torqued to 130 ft lbs? > am i missing something? thanks John M

Since I'm into mine right now, I can tell you they run at crankshaft speed. In fact, thanks from some great help from list participants, I can tell you that the "lobes" on the balance shaft are supposed to be 180 degrees out of phase with the crankshaft. This means that when the piston is at TDC, the lobes on both balance shafts are at BDC. In fact, that's the problem with my bike. I bought it cheap with the full knowledge that it needs some work and although it runs OK, I thought the vibration was excessive. That's why I pulled the cover to inspect the balance system. Weelll, it's obvious that the rotor's been off before and guess what, the lower balance shaft is 180 degrees out of time from where it's supposed to be. I can't see the top one yet but I bet it is too. Even if the top one is where it's supposed to be, at best the two counterbalancers are cancelling each other out. So, no wonder it vibrates like a industrial strengh massager. I ordered a puller from Jake at Sagebrush this afternoon to finish the job. It'll be interesting to see how er uh, smooth(?), the thumper becomes when the shafts are timed properly. Jim --- In DSN_klr650@yahoogroups.com, Zachariah Mully wrote:

> On Fri, 2003-04-25 at 11:25, Devon Jarvis wrote: > > Zachariah Mully wrote: > > > > > > > > > *The balancer system rotates at 2x (or half, I can never get

this

> > > straight) > > > > Trivial and irrelevant, but I think the balancer runs AT > > crankshaft speed since the crankshaft and balancer sprockets > > are the same size. The CAMSHAFT runs at 1/2 engine speed > > since the cam sprockets are 2x the size of the camchain > > drive sprocket on the end of the crank. > > > > Right right right... > > The issue I meant to explain is that all three sprockets have 18

teeth

> and the chain has 70 links, so by Prof Jim's calculations you might

need

> to rotate the engine 140 times before the plated links line up

(don't

> ask where I got 15 from, it's been a very miz week). Or you could

just

> count the offsets. > > Z > DC > A5X > A12X