Wilsons Sandbox

Per my last, lengthy post, the washer in this photo (http://autos.ph.groups.yahoo.com/group/DSN_KLR650/photos/view/a044?b=2) was found in the sump of my 2007. It is about an inch across and 2mm thick. For your amusement it is pictured with the broken doohickey which provided the occasion for the mystery washer's discovery. Thanks in advance for your response! Mark

--- In DSN_KLR650@yahoogroups.com, "Mark Harfenist" wrote:

> > Per my last, lengthy post, the washer in this photo > (http://autos.ph.groups.yahoo.com/group/DSN_KLR650/photos/view/a044?b=2) > was found in the sump of my 2007. It is about an inch across and 2mm > thick. For your amusement it is pictured with the broken doohickey > which provided the occasion for the mystery washer's discovery. >

A washer in those dimensions (hard to tell just what the scale is even with the quadrant right there for reference) might be something that goes under the head of a head bolt or the nut on a cylinder stud. I don't recall what the KLR has there so I have no idea if that's it, or if the one pictured is too big.

I don't remember anything like that when I did valve jobs or the doohickey. If it didn't drop from above (down through the timing chain gallery) maybe it is a washer (sharp-edged hard metal like the doo) that is a spacer in the tranny gears. Not to worry, you have one at the right place. This one is an extra. Don R100, A6F --- In DSN_KLR650@yahoogroups.com, "Mark Harfenist" wrote:

> > Per my last, lengthy post, the washer in this photo > (http://autos.ph.groups.yahoo.com/group/DSN_KLR650/photos/view/a044?

b=2)

> was found in the sump of my 2007. It is about an inch across and 2mm > thick. For your amusement it is pictured with the broken doohickey > which provided the occasion for the mystery washer's discovery. > > Thanks in advance for your response! > > Mark >

--- In DSN_KLR650@yahoogroups.com, "Mark Harfenist" wrote:

> > Per my last, lengthy post, the washer in this photo > (http://autos.ph.groups.yahoo.com/group/DSN_KLR650/photos/view/a044?b=2) > was found in the sump of my 2007. It is about an inch across and 2mm > thick. For your amusement it is pictured with the broken doohickey > which provided the occasion for the mystery washer's discovery. > > Thanks in advance for your response! > > Mark >

Mark, I think that is a thrust washer. When the inner case is removed, the idler shaft (the shaft the doohickey fits onto)is sometimes pulled a bit out of the engine case. When this happens, it's possible to drop the thrust washer that goes behind the idler sprocket. The idler sprocket is the bottom sprocket that moves a bit to take slack from the chain when the lever/doo is adjusted. To put it back into place you'd need to go all the way back in, removing the rotor, inner case, etc. Remove the spring so the idler shaft, bearing, and sprocket can be removed. There is a shallow recess on the back side of that chain sprocket, and the recessed side goes toward the inner case, with that thrust washer in the recess. I put it all back into place by stacking all the parts on my little finger on my right hand: fist on the finger is the outer (larger and thinner washer, the sprocket and bearing, then the thrust washer. Tilt the sprocket so it goes into the chain and use the little finger to find the hole in the engine case. Use the left hand to push all this stuff against the inner case so things dont drop, pull the right hand away, reach down, pick up the shaft with the spring lever and wiggle it into place inside the sprocket and bearing. Remember the thrust washer goes in the recess, against the engine case. This sprocket can wipe out the left side of the engine if it gets flung around after startup instead of sliding down into the case.... I'm about 95% sure that's what this part is..... all the best, Mike Eagle

At 1:51 PM +0000 6/17/08, Mike wrote:

>I think that is a thrust washer. When the inner case is removed, the >idler shaft (the shaft the doohickey fits onto)is sometimes pulled a >bit out of the engine case. When this happens, it's possible to drop >the thrust washer that goes behind the idler sprocket.

That was my first guess too, but I didn't chime in because it's an '07 with the stock doohickey. How did this washer become "at large?" Ah... but now after reading the original post prior to the photo link, I see that the doohicky was toasted once before and replaced with another stock doo! So, yup, my money's on the washer as Eagle Mike suggested. Mark

On 6/17/08 9:40 AM, "Tengai Mark Van Horn" wrote:

> > > > At 1:51 PM +0000 6/17/08, Mike wrote: >> >I think that is a thrust washer. When the inner case is removed, the >> >idler shaft (the shaft the doohickey fits onto)is sometimes pulled a >> >bit out of the engine case. When this happens, it's possible to drop >> >the thrust washer that goes behind the idler sprocket. > > That was my first guess too, but I didn't chime in because it's an > '07 with the stock doohickey. How did this washer become "at large?" > > Ah... but now after reading the original post prior to the photo > link, I see that the doohicky was toasted once before and replaced > with another stock doo! > So, yup, my money's on the washer as Eagle Mike suggested. > > Mark > >

Yeah....I seem to remember that very washer slipping out during a tech session a Fred s in Moab Eagle Mike was conducting, baton in hand. Bogdan [Non-text portions of this message have been removed]

I posted a couple of weeks ago asking about an unidentified washer found in my oil sump along with a broken bit of doohickey. The bike in question (2007) had had a warranty repair around 12k miles following a doohickey failure, but the dealership refused to use anything but identical Kawasaki parts. The current repair is therefore its second doohickey replacement, at about 20k miles. There is a photo of the washer alongside the broken doohickey in the archives. Responses attempting to identify the mystery part varied, and I forwarded them all to the guy doing the actual work in Europe. In case anyone is following this with as much interest as I (dubious), here's the response from my mechanic friend in Spain: (begin paste) First prize goes to Eagle Mike, yep it was the washer from behind the tensioner sprocket. I realised after I wrote last time that If it had have come down the cam chain gallery that it wouldn't have got into the sump if I couldn't get it out! doh I have been working on your bike with it on a lift upright, I hadn't had the idler sprocket shaft pulled out of the engine (I was careful when removing the cover), until I checked to see if the washer was missing, when I did remove the sprocket it unmasked a hole big enough for the washer to go through! My guess is whoever replaced the last Do had your bike leaned over to the right, pulled the shaft out with the cover & the washer disappeared down the hole, that would be REALLY clumsy, but it's the only possibility I think. So gold star to mike, it's one of those things you get to know from experience, I would never have known it was missing if he hadn't suggested it. (end paste) The only remaining mystery is: are there likely ill effects due to running the bike without this thrust washer for eight or ten thousand miles? So thanks again to all who responded, and thanks in particular to Eagle Mike, who once again proved his value to KLR owners worldwide. enjoy, Mark

--- In DSN_KLR650@yahoogroups.com, Mark Harfenist wrote: > > Thanks to Jud, Don, Mike, Mark, Bogdan for your responses to my query about a mystery washer found in my sump. Of the possibilities, the thrust washer seems the most likely, but I've forwarded all answers to my caretaker/mechanic/bike storage friend for his consideration. I continue to be in awe of the care, consideration and support always in evidence in this group. > > The puzzle from my perspective (never having split a case myself, or even seen one split) is as follows: no matter where this washer came from, it could not be fished out of the engine sump from the left (doohickey) side of the engine. Instead, it could only be retrieved along with the broken bit of doohickey from the right side behind the oilscreen. So.... if it couldn't be gotten out, how did it get in there in the first place? > > Your carefully considered ideas, dramatic concepts and wildest fantasies are all welcome. > > Thanks. > > Mark >

There is a company that advertised in the BMWMOA that make accessory lights mounts and sells lights. He had been working on the KLR mount. You might look at his sight and ask for any pictures he has for a KLR. the company is http://www.lumalink.com/ I have no affiliation with the company but have used his mounts on R1150GS as well as K1200GT. Mike Hilton

----- Original Message ----- From: David C. To: DSN_KLR650@yahoogroups.com Sent: Sunday, June 29, 2008 2:00 PM Subject: [DSN_KLR650] Driving lights? Anyone using driving lights? What kind? How mounted? Other experiences? Anyone using HIDs? Thanks Dave C [Non-text portions of this message have been removed]