pelham, al

[TexasThumpin@aol.com]

In a message dated 2/3/02 10:02:22 PM Central Standard Time, DSN_klr650@yahoogroups.com writes:

> Does anyone have any tips when it comes to > dissassembling and lubing the swingarm or > is it fairly straight forward? > > The service manual doesn't to a good job > expalining the procedure.

It is fairly straight forward. Take every thing off except the air box and sub frame. Bag and label any hardware or spacers to prevent having "extra" parts when you think you are done. I have just finished my cleaning and lubing, now I am just waiting for word on a new shock. My stock one is shot. Not surprised since I'm about 270 and I ride hard and I crash hard. . Check out the two little holes in the frame mounting area, they are probably about .063" in diameter. That is where I stuck my needle valve and pumped the area full of grease. See my earlier posting on the procedure I followed. While you are at it, stick your head under the rear fender and look up. You will probably find that the wiring needs some help from you. Good cold and wet day project. Have fun. Jim Texas Thumpin [Non-text portions of this message have been removed]

[Charles Marsh]

I recently cleaned and lubed my rear suspension. I cant get the plastic covers for the end of the swingarm bolt to want to stay in. Do they need replaced after each maintenance or can I just RTV them in place. TIA

[Ed Chait]

I installed some 1.5" lowering links on my KLR and decided that I would do the swingarm maintenance at the same time. My KLR is a 2003, almost all street miles, and the swingarm had never been serviced. I used the Marknet website as a guide as Mark's article on valve adjustment had served me well in the past on my first valve adjustment. The swingarm main bolt and the Unitrak suspension bolt both came out without too much trouble. A nice big rubber mallet helped:). The swingarm bolt was OK, but dry and without grease. The Unitrak bolt had significant corrosion in the center section which I removed as best I could. The sleeve that corresponds to that bolt also had significant corrosion. I wrapped some sandpaper around a dowel and cleaned that up also before applying lots of grease. All of the needle bearings had *very* little grease from the factory. I greased everything up well and was just done buttoning everything back together with my new lowering links when I reached for the chain to guide it over the rear sprocket. OOPS!, I had forgotten to position the chain over the swingarm and I had to take the swingarm off again. Guarantee I won't make that mistake twice:). I also lowered the front of the bike by raising the forks 1.5" in the triple trees. One of the nuts on one of the pinch bolts was very tight and I rounded it off a bit trying to loosen it. Those nuts seem to be as soft as many of the other fasteners on a KLR. So the project went well in general except for taking a bit longer due to my lack of attention to positioning the chain before reinstalling the swingarm. I cranked the preload and damping up a bit on the rear shock to account for the softening effect of the longer links and I'm very happy with the modestly lower stance and the handling. I also installed the shorter kickstand so that the bike would be at the proper angle when parked. To remove the kickstand spring I used a needlenose pliers to push pennies in between the spring coils. That trick worked very well. I would like to replace the pinch bolt nuts with something a bit harder. Anyone know what size and thread these nuts are? ed A17

[Garrett Smith]

Hi Ed, Your experience is similar to mine. I just did my swing arm and had the same trouble. My pivot bolt was really tough to get out as the drain holes (yeah right) were plugged and the bolt was bathed in rusty water for who-knows-how-long. I replaced the swing arm bearings which were sloppy, the pivot and bushing which were severely pitted and slathered everything in waterproof grease. Did my valves too and replaced the OEM shock with the re-worled version form MultiSurfaceMotorcycling.com. I forgot that darn chain too. Time to ride! Regards, Garrett Ed Chait wrote: I installed some 1.5" lowering links on my KLR and decided that I would do the swingarm maintenance at the same time. My KLR is a 2003, almost all street miles, and the swingarm had never been serviced. I used the Marknet website as a guide as Mark's article on valve adjustment had served me well in the past on my first valve adjustment. The swingarm main bolt and the Unitrak suspension bolt both came out without too much trouble. A nice big rubber mallet helped:). The swingarm bolt was OK, but dry and without grease. The Unitrak bolt had significant corrosion in the center section which I removed as best I could. The sleeve that corresponds to that bolt also had significant corrosion. I wrapped some sandpaper around a dowel and cleaned that up also before applying lots of grease. All of the needle bearings had *very* little grease from the factory. I greased everything up well and was just done buttoning everything back together with my new lowering links when I reached for the chain to guide it over the rear sprocket. OOPS!, I had forgotten to position the chain over the swingarm and I had to take the swingarm off again. Guarantee I won't make that mistake twice:). I also lowered the front of the bike by raising the forks 1.5" in the triple trees. One of the nuts on one of the pinch bolts was very tight and I rounded it off a bit trying to loosen it. Those nuts seem to be as soft as many of the other fasteners on a KLR. So the project went well in general except for taking a bit longer due to my lack of attention to positioning the chain before reinstalling the swingarm. I cranked the preload and damping up a bit on the rear shock to account for the softening effect of the longer links and I'm very happy with the modestly lower stance and the handling. I also installed the shorter kickstand so that the bike would be at the proper angle when parked. To remove the kickstand spring I used a needlenose pliers to push pennies in between the spring coils. That trick worked very well. I would like to replace the pinch bolt nuts with something a bit harder. Anyone know what size and thread these nuts are? ed A17 Garrett Smith Calgary Alberta www.adventuremototech.com 1-877-216-7927 --------------------------------- Be smarter than spam. See how smart SpamGuard is at giving junk email the boot with the All-new Yahoo! Mail [Non-text portions of this message have been removed]

[Norm Keller]

Anyone who doe not routinely remove and grease the long engine and suspension bolts is asking for some really interesting experience in removing frozen bolts. (VBG) Don't let it be you, Norm [Non-text portions of this message have been removed]

[Garrett Smith]

Yup, It's true. After cursing, swearing, gnashing my teeth, banging my head, smashing my knuckles, cutting my finger, questioning the lineage of anyone that happened across me as I worked, cursed every Deity that I could think of, made a deal with the devil , pounded, filed, sprayed and then did all the above again...I finally got the swing arm and pivot assembly apart. As Norm said, I will be routinely doing this now, every 6 months or so, to avoid all the above unpleasantness. Incidentally there wasn't much grease on the swing arm and pivot assembly bolt and bearings. There is now. I bought the bike second hand but new bikes should have this done this too....you've been warned Garrett Smith www.adventuremototech.com Norm Keller wrote: Anyone who doe not routinely remove and grease the long engine and suspension bolts is asking for some really interesting experience in removing frozen bolts. (VBG) Don't let it be you, Norm [Non-text portions of this message have been removed] --------------------------------- Be smarter than spam. See how smart SpamGuard is at giving junk email the boot with the All-new Yahoo! Mail [Non-text portions of this message have been removed]

[Norm Keller]

Or do about an hour more work and install grease nipples. Then, pump in some grease with no problems. Norm Progress goaded by laziness.

>I will be routinely doing this now, every 6 >months or so, to avoid all the above >unpleasantness. Incidentally there wasn't much >grease on the swing arm and pivot assembly >bolt and bearings. There is now.

[Non-text portions of this message have been removed]

[Zachariah Mully]

Garrett Smith wrote:

> Yup, > > It's true. After cursing, swearing, gnashing my teeth, banging my head, smashing my knuckles, cutting my finger, questioning the lineage of anyone that happened across me as I worked, cursed every Deity that I could think of, made a deal with the devil , pounded, filed, sprayed and then did all the above again...I finally got the swing arm and pivot assembly apart. > > As Norm said, I will be routinely doing this now, every 6 months or so, to avoid all the above unpleasantness. Incidentally there wasn't much grease on the swing arm and pivot assembly bolt and bearings. There is now. > > I bought the bike second hand but new bikes should have this done this too....you've been warned > > Garrett Smith > > www.adventuremototech.com > > > > Norm Keller wrote: > Anyone who doe not routinely remove and grease the long engine and suspension bolts is asking for some really interesting experience in removing frozen bolts. (VBG) > > Don't let it be you, > > Norm

Yup, if anyone wants to see quite how bad those bolts can freeze, you're welcome to take one of the frames I have with a frozen Uni-Trak bolt. I've had it in my 12ton shop press to the point where I was trying to pump the press from around the corner I was so scared of the amount pressure I was applying to the bolt. Nada. Still frozen. Z

[Rocky]

I know there are a few other KLR owners in my area, because I have seen them. I am trying to get a bike night going at a sports bar in Pelham. If you are one of the riders in my area and are interested, drop me an email and I will give you the details as they become available. I have gone to several bike nights in the greater Birmingham area, and so far I am the only KLR, heck, the only dual sport rider that shows. Thanks, Rocky