(the weakest) master link

[jstotler]

I replaced my chain and rear sprocket a couple of weeks ago. The front sprocket looked to be very new (I bought the bike used about a thousand miles ago), so I ignored everyone's advice like a moron and didn't install a new front sprocket at the same time. This was about 500 miles ago. This morning on my way to work I heard a loud sort of CRACK noise, and threw the new chain. The master link was gone, which made sense. What doesn't make sense is that the engine will not start. It didn't seize, as when I thumb the starter everything seems to be churning just fine, but there's no fire, almost like there's no spark or something. Can anyone suggest where I should start on finding why it won't fire? Sorry for such a newbie question, but I've just started doing my own work on bikes in the last year, and I'm kind of flailing around in the dark a bit. thanks, john

[Pierre]

you probably destroyed the neutral switch: it's just in front of the front sprocket Pierre

----- Original Message ----- From: "JStotler" To: DSN_klr650@yahoogroups.com> Sent: Thursday, May 06, 2004 11:22 AM Subject: [DSN_klr650] Very vague question > I replaced my chain and rear sprocket a couple of weeks ago. The > front sprocket looked to be very new (I bought the bike used about a > thousand miles ago), so I ignored everyone's advice like a moron and > didn't install a new front sprocket at the same time. This was about > 500 miles ago. > > This morning on my way to work I heard a loud sort of CRACK noise, > and threw the new chain. > > The master link was gone, which made sense. > > What doesn't make sense is that the engine will not start. > > It didn't seize, as when I thumb the starter everything seems to be > churning just fine, but there's no fire, almost like there's no spark > or something. > > Can anyone suggest where I should start on finding why it won't fire? > > Sorry for such a newbie question, but I've just started doing my own > work on bikes in the last year, and I'm kind of flailing around in > the dark a bit. > > > thanks, > john > > > > 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 > > > > > > >

[Zachariah Mully]

On Thu, 2004-05-06 at 14:22, JStotler wrote:

> I replaced my chain and rear sprocket a couple of weeks ago. The > front sprocket looked to be very new (I bought the bike used about a > thousand miles ago), so I ignored everyone's advice like a moron and > didn't install a new front sprocket at the same time. This was about > 500 miles ago.

This is irrelevant to your problem.

> > This morning on my way to work I heard a loud sort of CRACK noise, > and threw the new chain. > > The master link was gone, which made sense.

How does loosing your master link have any relationship to your replacement of the sprockets? Apparently you didn't install the master link correctly (backing the pins out onto the plate).

> What doesn't make sense is that the engine will not start.

When the chain broke, it probably cut the stator wires which are directly infront of the sprocket.

> It didn't seize, as when I thumb the starter everything seems to be > churning just fine, but there's no fire, almost like there's no spark > or something.

With the stator wires cut, the ignition system has no idea when to fire the spark plug.

> Can anyone suggest where I should start on finding why it won't fire?

Pull the sprocket cover. You'll probably see that the wires beneath it got chewed up. Curse a whole lot, then get out your soldering iron and some heatshrink tubing and solder everything back together. Z DC A5X A12X

[Zachariah Mully]

On Thu, 2004-05-06 at 14:37, JStotler wrote:

> --- In DSN_klr650@yahoogroups.com, Zachariah Mully wrote: > > Apparently you didn't install the master > > link correctly (backing the pins out onto the plate). > > > Backing the pins out onto the plate?

Actually I said it backwards, backing the plate out onto the clip. The ML clip rides in two grooves on the pins, and with certain chain breakers, you can sandwich the clip in grooves by backing the side plate behind the clip out onto the clip. This'll prevent the clip from shooting off. Z DC A5X A12X

[James L. Miller Jr.]

Uh, yep. My thoughts exactly. If you're lucky, all that happened was the wires got cut. 20 minutes with an iron and you're riding. If it tweaked your sprocket or countershaft, you'll notice a lot more going wrong really quickly. Keep that credit card handy. You're gonna need it. millerized (been there, done that, still paying!) --- In DSN_klr650@yahoogroups.com, Zachariah Mully wrote:

> > With the stator wires cut, the ignition system has no idea when to

fire

> the spark plug. >> Pull the sprocket cover. You'll probably see that the wires

beneath it

> got chewed up. Curse a whole lot, then get out your soldering iron

and

> some heatshrink tubing and solder everything back together. > > Z > DC > A5X > A12X

[bigfatgreenbike]

lists@... wrote:

>I replaced my chain and rear sprocket a couple of weeks ago. The >front sprocket looked to be very new (I bought the bike used about a >thousand miles ago), so I ignored everyone's advice like a moron and >didn't install a new front sprocket at the same time. This was about >500 miles ago. > >This morning on my way to work I heard a loud sort of CRACK noise, >and threw the new chain. > >The master link was gone, which made sense. > >What doesn't make sense is that the engine will not start. > >It didn't seize, as when I thumb the starter everything seems to be >churning just fine, but there's no fire, almost like there's no spark >or something. > >Can anyone suggest where I should start on finding why it won't fire? >

When you broke the chain, it bunched up between the countershaft sprocket and the case. It probably broke the countershaft cover and cut the wires from the stator that power the ignition. If there's no damage to the cases, then probably fixable with a soldering iron and shrink wrap. If the case is damaged, hoefully it's minor. I just got the pieces for a case-saver project, which would theoretically prevent this. I hope to have something in a few weeks. -- Devon Brooklyn, NY A15-Z '01 KLR650 '81 SR500 cafe racer "The truth's not too popular these days....." Arnold Schwarzenneger, in The Running Man

[Norm Keller]

Of course you are right about the cam base circle being round and so the valve stem clearance can be checked anywhere on the base circle. It is simply a matter of convenience that the engine is timed so that the maximum number of valves to be adjusted with the least turning of the engine. When grinding camshafts, the base circle (it is the round part opposite the lobe) is ground, round because that is the easiest way to finish that area accurately. Some small air cooled engines have a small "hump" in front of the main lobe to reduce compression during starting but this can be readily discerned. I simply make sure that I'm on the base circle well away from the start of the lobe and then check clearance. As you said, timing the camshaft precisely for the purpose of checking clearance isn't necessary. For the newbie it is likely good practice as it reduces the number of variables and pitfalls. HIH, Norm --------------------------------- Do you Yahoo!? Win a $20,000 Career Makeover at Yahoo! HotJobs [Non-text portions of this message have been removed]

[pete88chester]

Devon wrote: "When you broke the chain, it bunched up between the countershaft sprocket and the case. It probably broke the countershaft cover and cut the wires from the stator that power the ignition. If there's no damage to the cases, then probably fixable with a soldering iron and shrink wrap. If the case is damaged, hoefully it's minor. I just got the pieces for a case-saver project, which would theoretically prevent this. I hope to have something in a few weeks." I too had a problem with the plastic front chain/sprocket protector. The chain picked up a stone about as large as my thumb that jammed into the protector & broke a hole in it. It also put a little cut on the stator/alternator wire harness & broke off one of the small tabs on the engine case that guides the wire harness. I decided the plastic protector didn't provide enough protection, so made a stronger replacement. I made it out of 1 1/2" X 1/8" flat stock metal. It attaches to the engine at two points & also to the frame at two points near the swing arm pivot. I tried to lay it out so that if the chain breaks it won't jam, but who knows if it will work that way. I relocated the wires so they are in a hard plastic loom that runs in back of the inner balancer chain housing, up to the starter & back to the connector. Pete Chester A16

[bigfatgreenbike]

ppchester@... wrote:

>I too had a problem with the plastic front chain/sprocket protector. >The chain picked up a stone about as large as my thumb that jammed >into the protector & broke a hole in it. It also put a little cut on >the stator/alternator wire harness & broke off one of the small tabs >on the engine case that guides the wire harness. I decided the >plastic protector didn't provide enough protection, so made a >stronger replacement. I made it out of 1 1/2" X 1/8" flat stock >metal. It attaches to the engine at two points & also to the frame >at two points near the swing arm pivot. I tried to lay it out so >that if the chain breaks it won't jam, but who knows if it will work >that way. I relocated the wires so they are in a hard plastic loom >that runs in back of the inner balancer chain housing, up to the >starter & back to the connector. Pete Chester A16 >

Photos please! I am going make something out of a sheet of 1/4" stainless steel I have handy, the case savers I've seen (purpose built for woods bikes) basically have a steel rail that prevents the chain from jumping the countershaft sprocket at all. -- Devon Brooklyn, NY A15-Z '01 KLR650 '81 SR500 cafe racer "The truth's not too popular these days....." Arnold Schwarzenneger, in The Running Man

[Mike Torst]

Stator wires were cut when the chain got thrown is my guess. They are right in front of the engine sprocket. 4 wires. Mike Torst Las Vegas

> -----Original Message----- > From: JStotler [mailto:lists@...] > Sent: Thursday, May 06, 2004 11:23 AM > To: DSN_klr650@yahoogroups.com > Subject: [DSN_klr650] Very vague question > > I replaced my chain and rear sprocket a couple of weeks ago. The > front sprocket looked to be very new (I bought the bike used about a > thousand miles ago), so I ignored everyone's advice like a moron and > didn't install a new front sprocket at the same time. This was about > 500 miles ago. > > This morning on my way to work I heard a loud sort of CRACK noise, > and threw the new chain. > > The master link was gone, which made sense. > > What doesn't make sense is that the engine will not start. > > It didn't seize, as when I thumb the starter everything seems to be > churning just fine, but there's no fire, almost like there's no spark > or something. > > Can anyone suggest where I should start on finding why it won't fire? > > Sorry for such a newbie question, but I've just started doing my own > work on bikes in the last year, and I'm kind of flailing around in > the dark a bit. > > > thanks, > john > > > > 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 > > > >