starter gear bushing failure

[bentwall2003]

Please send any info/websites on rebuilding KLR650 rear shocks. Mine is bouncing me down the trail and I cannot afford a new one. Thanks, Keith

[Wayne Watson]

Did you try Dual-Star? bentwall2003 wrote:Please send any info/websites on rebuilding KLR650 rear shocks. Mine is bouncing me down the trail and I cannot afford a new one. Thanks, Keith 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 . Yahoo! Groups Links --------------------------------- Do you Yahoo!? Yahoo! Tax Center - File online by April 15th [Non-text portions of this message have been removed]

[Jean-Philippe Granger]

http://calgarydualsport.tripod.com/klr650shock/procedure.html Never used this, but if I decided to rebuild that spare shock, that's where I'm getting my info... JP Granger A12 Montreal -----Original Message----- From: Wayne Watson [mailto:nenaandwayne@...] Sent: April 15, 2004 4:29 PM To: bentwall2003; DSN_klr650@yahoogroups.com Subject: Re: [DSN_klr650] KLR Rear Shock rebuild Did you try Dual-Star? bentwall2003 wrote:Please send any info/websites on rebuilding KLR650 rear shocks. Mine is bouncing me down the trail and I cannot afford a new one. Thanks, Keith 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 . Yahoo! Groups Links --------------------------------- Do you Yahoo!? Yahoo! Tax Center - File online by April 15th [Non-text portions of this message have been removed] 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 . Yahoo! Groups Links

[Tengai Mark Van Horn]

I would just save myself the time and contact the folks at F1 engineering. http://www.f1engineering.com/contact.html They sell 2003 take-offs for $120.00. You can sometimes find them for $100.00 on ebay from the same guys. Mark http://www.reelrider.com At 7:10 PM +0100 4/15/04, Jean-Philippe Granger wrote:

>http://calgarydualsport.tripod.com/klr650shock/procedure.html > >Never used this, but if I decided to rebuild that spare shock, that's >where I'm getting my info... > > >JP Granger >A12 >Montreal > >-----Original Message----- >From: Wayne Watson [mailto:nenaandwayne@...] >Sent: April 15, 2004 4:29 PM >To: bentwall2003; DSN_klr650@yahoogroups.com >Subject: Re: [DSN_klr650] KLR Rear Shock rebuild > > >Did you try Dual-Star? > >bentwall2003 wrote:Please send any info/websites >on rebuilding KLR650 rear shocks. Mine >is bouncing me down the trail and I cannot afford a new one. >Thanks, >Keith

[Jeff Wight]

--- In DSN_klr650@yahoogroups.com, "dumbazz650" wrote:

> I have a theory about this, asa similar failure happened to me after > doing the doohickey on my '87 KLR. In that case, the two surfaces > on the inside of the rotor and the starter ring gear that mate up > with a thrust washer, were badly gauled and chewed up. I had to > replace both the rotor and starter ring gear, though I'm hoping a > machinist friend will be able to dress the surfaces up and I can > reuse the parts in a project bike. > > Prior to the failure, I remember very carefully putting the thing > together, wiping it down with clean lint-free rags, and then > assemblying and torqueing properly. The woodruff key was in the slot, > and everything was as it should be, but still the binding, gauling, > and damaged to the parts. > > In retrospect, I think it was the fact that the parts were DRY, as > in not coated with either OIL, or assembly lube, that caused the > failure. I believe these parts are only splash lubricated, and since > that failure, have done 7 more doohickeys, and I now make sure each > and every one of this is > 1. FIRST WIPED CLEAN with rags > 2 THEN DRIPPING FRESH WITH OIL. > 3. Then assemble as usual. > > In that lot of 7, I have had no failures of any kind. > > hope that helps, > MarkB

Your theory makes sense. I did the same thing you mentioned before reassembly, I wiped everything down so it went together dry. What did you do to remove the junk off the crankshaft? It looks like dried toothpaste (certainly bears no resemblance to the bushing that used to be). Thanks, -Jeff