electrical gremlin

[eriketucker]

MY 1999 KLR 65O with 5000 miles on it had developed a nocking noise when bike is at idle, I was able to get bike to dealer one day so they could hear it, and there diagnosis was the small end of the coneccting rod was egg shaped, and needs to be replaced, I said fine fix it. Got bike back almost a month latter,had it for one day and guess what, that identical knock was still there. bike sat there for another three weeks, they informed me that they thought it was the Cam Chain tensioner so they replaced it, this lasted for about 400 miles before the nock returned. bike is still at dealer. I called Kawasaki last week to let them know that this is been going on since October of 2003,and to please advise dealer with some tech help. What do you guys think. Sincerely, Erik

[R. Hoskins]

Erik, I had a similar problem several years ago. The problem was eventually chased down to a problem with between the cam shaft and the cam chain gear on the end of one of cam shafts. In my case the shear pin that kept the gear locked to the cam shaft had failed. As the gear rotated it would slip back and forth a little, and essentially drop the valves hard onto the seats making a very loud banging noise. That pin cost me a lot of money to find. Randy eriketucker wrote:

> > MY 1999 KLR 65O with 5000 miles on it had developed a nocking noise > when bike is at idle, I was able to get bike to dealer one day so > they could hear it, and there diagnosis was the small end of the > coneccting rod was egg shaped, and needs to be replaced, I said fine > fix it. Got bike back almost a month latter,had it for one day and > guess what, that identical knock was still there. bike sat there for > another three weeks, they informed me that they thought it was the > Cam Chain tensioner so they replaced it, this lasted for about 400 > miles before the nock returned. bike is still at dealer. I called > Kawasaki last week to let them know that this is been going on since > October of 2003,and to please advise dealer with some tech help. > What do you guys think. > > Sincerely, > > Erik > > L

[mark hanke]

Don, I don't know what's wrong with your KLR butt I didn't see any water on the course! I enjoyed meeting and camping near you and the Dana's, see ya next time. Thanks for the t- shirt. Mark Hanke ----- Original Message -

> I was in the middle of the Devil's Creek DS ride this weekend when my > KLR650 starting having a strange electrical problem. I would start > the bike, put it in gear, kickstand UP, and as I would let the clutch > out, the engine would die. . Let me > say there was a LOT of water and sand on this ride, up and over my > boots.