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klr650 : was bent handle bar now is cracked handle bar !!
Posted: Thu Oct 09, 2008 10:16 am
by Luc Legrain
Of course I tried the easy way out to straighten the bar ( pipe, pull )
it cracked at the cross bar weld .
How complicated is the process of replacing handle bar, specially the throttle side ? Is it just a matter of " take it off, put it back on " or is it more complicated ?
Thanks
klr650 : was bent handle bar now is cracked handle bar !!
Posted: Thu Oct 09, 2008 2:12 pm
by Jeff Saline
On Thu, 9 Oct 2008 08:16:16 -0700 (PDT) Luc Legrain
writes:
> Of course I tried the easy way out to straighten the bar ( pipe,
> pull )
> it cracked at the cross bar weld .
> How complicated is the process of replacing handle bar, specially
> the throttle side ? Is it just a matter of " take it off, put it
> back on " or is it more complicated ?
> Thanks
<><><><><><><><><>
<><><><><><><><><>
Luc,
It's pretty much a take it off, put it back on situation. May I suggest
you replace your grips since the old ones may be glued on extremely well
and get damaged when removing the clutch side. You may find it easiest
to keep the bars loose so you can move them from side to side when
sliding the throttle housing off the old and onto the new.
Nothing needs to get torqued so tight that you have to grunt and groan in
this swap.
I like using RTV as a grip glue since it acts like a lube when sliding
the grip on and then drys like a glue. And it's easy to remove at a
later date. Some folks will suggest hair spray or soap for this and I
suppose both will work too.
Make sure when you install the throttle you don't slide it so far inboard
on the bar that the end of the tube sticks on the end of the bar. That
can give you a sticky throttle.
Best,
Jeff Saline
ABC # 4412 South Dakota Airmarshal
Airheads Beemer Club
www.airheads.org
The Beautiful Black Hills of South Dakota
75 R90/6, 03 KLR650, 79 R100RT
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klr650 : was bent handle bar now is cracked handle bar !!
Posted: Thu Oct 09, 2008 3:04 pm
by Kevin Powers
The hardest part will be choosing a new bar and grips. If I remember right
you have to file off a locater tab on the clutch side. Pay attention to the
location of all the cable and hose routing before you remove the existing
bar - digital photos help with that.
--
Kevin Powers
White Bear Lake, MN
On Thu, Oct 9, 2008 at 10:16 AM, Luc Legrain wrote:
> Of course I tried the easy way out to straighten the bar ( pipe, pull )
> it cracked at the cross bar weld .
> How complicated is the process of replacing handle bar, specially the
> throttle side ? Is it just a matter of " take it off, put it back on " or is
> it more complicated ?
> Thanks
>
>
>
[Non-text portions of this message have been removed]
klr650 : was bent handle bar now is cracked handle bar !!
Posted: Thu Oct 09, 2008 5:31 pm
by Jeff Saline
On Thu, 9 Oct 2008 15:04:27 -0500 "Kevin Powers"
writes:
> The hardest part will be choosing a new bar and grips. If I remember
> right
> you have to file off a locater tab on the clutch side. Pay
> attention to the
> location of all the cable and hose routing before you remove the
> existing
> bar - digital photos help with that.
> --
> Kevin Powers
> White Bear Lake, MN
<><><><><><><>
<><><><><><><>
Kevin,
You are so right with the nub needing to be removed. I did this with a
guy about 2 months ago and forgot all about that nub. We used a dremel
tool with a drum sander on it but a file would work well too.
Best,
Jeff Saline
ABC # 4412 South Dakota Airmarshal
Airheads Beemer Club
www.airheads.org
The Beautiful Black Hills of South Dakota
75 R90/6, 03 KLR650, 79 R100RT
____________________________________________________________
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klr650 : was bent handle bar now is cracked handle bar !!
Posted: Thu Oct 09, 2008 10:24 pm
by Jud Jones
--- In
DSN_KLR650@yahoogroups.com, Jeff Saline wrote:
>
> On Thu, 9 Oct 2008 15:04:27 -0500 "Kevin Powers"
> writes:
> > The hardest part will be choosing a new bar and grips. If I remember
> > right
> > you have to file off a locater tab on the clutch side. Pay
> > attention to the
> > location of all the cable and hose routing before you remove the
> > existing
> > bar - digital photos help with that.
> > --
> > Kevin Powers
> > White Bear Lake, MN
> <><><><><><><>
> <><><><><><><>
>
> Kevin,
>
> You are so right with the nub needing to be removed. I did this with a
> guy about 2 months ago and forgot all about that nub. We used a dremel
> tool with a drum sander on it but a file would work well too.
>
As I recall, I just snapped it off with a plier, then scraped it smooth with a bench knife.
klr fastners
Posted: Fri Oct 10, 2008 6:31 pm
by maudibbb
Hello Folks! I was wondering if anyone has compiled a list of all
fasteners on the "classic" KLR? This would include type & size of all
fasteners such as bolt, screw, pan-head, flat head, hex-head,
Phillips, slot-head, Allen hex, thread, length, diameter etc. Also
such information such as correct size of tool for each fastener.