helmets nklr

[Mike Atkinson]

Last fall I cracked the clutch cover on my 2005 and had to replace it. Apparently when I installed the new clutch cover I did not fasten the nut on the water pump correctly. I noticed when I ran the bike it was overheating with leakage of radiator fluid and upon further inspection noticed a very large crack in the water pump cover. After removing the water pump cover I noticed a lot of metal shavings in the catch bucket I used to catch the radiator fluid. Sure enough, the impeller was chewed up and the nut that holds it onto the impeller shaft had broken off and was spinning around inside the water pump causing the metal shavings. My questions are as follows: 1. Is is a difficult job to replace the impeller shaft myself? I am only a moderately skilled mechanic. 2. What the "H" could I have done wrong to cause the nut on the impeller shaft to shear off? Did I under/over tighten? 3. I am thinking of taking the bike to a cycle shop and having them do the repairs and since the impeller shaft will have to be replaced should I go ahead and have the "doohicky" replaced as well? Thanks guys. Muddy Shoe Mike "05 KLR" rider [Non-text portions of this message have been removed]

[Mike Hansen]

you have to tear down the engine. the book calls for 7.5hrs. the dealer wanted $900.00 in labor plus parts to perform the job when mine broke. I over tightened the nut stretching the shaft and it broke off. Take a photo and post it. I was able to grind down the face of my impeller to allow more shaft exposure. I tapped the shaft a fe more threads deeper and grinded the nut down to get rid of the bevel and have just straight threads. I used red lock-tite to seal the deal. 3500 miles later and no failure yet. -Mike- ________________________________ From: Mike Atkinson To: DSN_KLR650@yahoogroups.com Sent: Friday, March 20, 2009 11:30:25 AM Subject: [DSN_KLR650] Balancer shaft replacement Last fall I cracked the clutch cover on my 2005 and had to replace it. Apparently when I installed the new clutch cover I did not fasten the nut on the water pump correctly. I noticed when I ran the bike it was overheating with leakage of radiator fluid and upon further inspection noticed a very large crack in the water pump cover. After removing the water pump cover I noticed a lot of metal shavings in the catch bucket I used to catch the radiator fluid. Sure enough, the impeller was chewed up and the nut that holds it onto the impeller shaft had broken off and was spinning around inside the water pump causing the metal shavings. My questions are as follows: 1. Is is a difficult job to replace the impeller shaft myself? I am only a moderately skilled mechanic. 2. What the "H" could I have done wrong to cause the nut on the impeller shaft to shear off? Did I under/over tighten? 3. I am thinking of taking the bike to a cycle shop and having them do the repairs and since the impeller shaft will have to be replaced should I go ahead and have the "doohicky" replaced as well? Thanks guys. Muddy Shoe Mike "05 KLR" rider [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[Ross Lindberg]

--- In DSN_KLR650@yahoogroups.com, Mike Atkinson wrote:

> > Last fall I cracked the clutch cover on my 2005 and had to replace it. Apparently when I installed the new clutch cover I did not fasten the nut on the water pump correctly. > I noticed when I ran the bike it was overheating with leakage of radiator fluid and upon further inspection noticed a very large crack in the water pump cover. > After removing the water pump cover I noticed a lot of metal shavings in the catch bucket I used to catch the radiator fluid. Sure enough, the impeller was chewed up and the nut that holds it onto the impeller shaft had broken off and was spinning around inside the water pump causing the metal shavings. > My questions are as follows: > 1. Is is a difficult job to replace the impeller shaft myself? I am only a moderately skilled mechanic. > 2. What the "H" could I have done wrong to cause the nut on the impeller shaft to shear off? Did I under/over tighten? > 3. I am thinking of taking the bike to a cycle shop and having them do the repairs and since the impeller shaft will have to be replaced should I go ahead and have the "doohicky" replaced as well? > Thanks guys. > Muddy Shoe Mike "05 KLR" rider >

Mike, what can I say other than "what a bummer". Well, these things do happen from time to time even to professional mechanics, so don't feel too bad. I can't tell you how big a job it is to replace the waterpump shaft, but I would recommend getting a Clymer's manual if you don't already have one. I have the Clymer's manual as well as both the Factory Kawasaki manuals, and I much prefer the Clymer's manual. As far as doing on "doo", that isn't a bad job at all. Get your Clymer's manual, print the instructions off the Mark Net site and go at it. It is simple enough that moderately skilled mechanic will have no trouble doing it. If you need the tools, drop me an e-mail and I'll send them out to you. I would be hesitant to have a motorcycle shop do the work, simply on the basis of cost. The Kawasaki dealer in Fargo has a shop rate of $120/hour. For comparison the best diesel shop in my area has a shop rate of $45/hour. What would take more skill to work on in your opinion; Kenworth or Kawasaki? Methinks the motorcycle shop is screwing over the public on service. I'm not bragging when I tell you this, but over my lifetime I have accumulated over $40,000 in mechanic and machinist tools. I honestly have more tools than most of the mechanics I know. I didn't wind up with this collection because of a well-paying job, I aquired it because I was too cheap/too broke to pay dealership prices for service. Let's use round numbers for figuring. Let's say you drop your bike off at the dealer and have them fix the waterpump shaft, replace the doo, set the valves, and give it a thorough "once-over" before they riding season. Let's say for easy figuring they bill you 10 hours. That's $1200! Plus parts. Plus shop supplies. Plus tax. The bill is going to be ugly! Now let's say you do the service yourself in the comfort of your own garage. You are going to be a little nervous and jumpy because of the waterpump incident, but that's okay. Let's say it takes you 20 hours to do the work. Easily a weekend project. Shop rate $0/hr. Shop supplies $20 or less. Sales tax $0. Parts are going to be the same or less as you'll have the chance to do some shopping online. The way I have it figured, you just saved at least $1200, plus you are now an authority on waterpump shaft replacement, so you can talk me through it if mine ever fails. Spend the $1200 on farkle, tools, a romantic weekend with the wife, etc. I'm a little long-winded, but I would encorage you to fix it yourself and have some fun doing it. Ross Lindberg Fertile, MN

[roncriswell@sbcglobal.net]

I think you are correct. You never know how competent the dealership guys are anyway. I figure by doing most things on my KLR and Concours over the last few years (even the KLR water pump seal) I have saved probably 4 grand. I took a couple classes at the local Jr College which really helped. Now I need to take a class to figure out my weed eater and weed blower to figure out why they won't run right even using special non ethanol gas, with stabil and oil already added? 2 strokes so simple but sometimes a mystery. I have always wanted another Ducati .... but the desmo valves intimidate me and I won't do like a Doctor I know with a 998 that spends $1000 bill every time he takes it in. Criswell

On Mar 20, 2009, at 2:37 PM, Ross Lindberg wrote: > --- In DSN_KLR650@yahoogroups.com, Mike Atkinson > wrote: > > > > Last fall I cracked the clutch cover on my 2005 and had to > replace it. Apparently when I installed the new clutch cover I did > not fasten the nut on the water pump correctly. > > I noticed when I ran the bike it was overheating with leakage of > radiator fluid and upon further inspection noticed a very large > crack in the water pump cover. > > After removing the water pump cover I noticed a lot of metal > shavings in the catch bucket I used to catch the radiator fluid. > Sure enough, the impeller was chewed up and the nut that holds it > onto the impeller shaft had broken off and was spinning around > inside the water pump causing the metal shavings. > > My questions are as follows: > > 1. Is is a difficult job to replace the impeller shaft myself? I > am only a moderately skilled mechanic. > > 2. What the "H" could I have done wrong to cause the nut on the > impeller shaft to shear off? Did I under/over tighten? > > 3. I am thinking of taking the bike to a cycle shop and having > them do the repairs and since the impeller shaft will have to be > replaced should I go ahead and have the "doohicky" replaced as well? > > Thanks guys. > > Muddy Shoe Mike "05 KLR" rider > > > > Mike, what can I say other than "what a bummer". Well, these things > do happen from time to time even to professional mechanics, so > don't feel too bad. I can't tell you how big a job it is to replace > the waterpump shaft, but I would recommend getting a Clymer's > manual if you don't already have one. I have the Clymer's manual as > well as both the Factory Kawasaki manuals, and I much prefer the > Clymer's manual. > > As far as doing on "doo", that isn't a bad job at all. Get your > Clymer's manual, print the instructions off the Mark Net site and > go at it. It is simple enough that moderately skilled mechanic will > have no trouble doing it. If you need the tools, drop me an e-mail > and I'll send them out to you. > > I would be hesitant to have a motorcycle shop do the work, simply > on the basis of cost. The Kawasaki dealer in Fargo has a shop rate > of $120/hour. For comparison the best diesel shop in my area has a > shop rate of $45/hour. What would take more skill to work on in > your opinion; Kenworth or Kawasaki? Methinks the motorcycle shop is > screwing over the public on service. > > I'm not bragging when I tell you this, but over my lifetime I have > accumulated over $40,000 in mechanic and machinist tools. I > honestly have more tools than most of the mechanics I know. I > didn't wind up with this collection because of a well-paying job, I > aquired it because I was too cheap/too broke to pay dealership > prices for service. Let's use round numbers for figuring. Let's say > you drop your bike off at the dealer and have them fix the > waterpump shaft, replace the doo, set the valves, and give it a > thorough "once-over" before they riding season. Let's say for easy > figuring they bill you 10 hours. That's $1200! Plus parts. Plus > shop supplies. Plus tax. The bill is going to be ugly! > > Now let's say you do the service yourself in the comfort of your > own garage. You are going to be a little nervous and jumpy because > of the waterpump incident, but that's okay. Let's say it takes you > 20 hours to do the work. Easily a weekend project. Shop rate $0/hr. > Shop supplies $20 or less. Sales tax $0. Parts are going to be the > same or less as you'll have the chance to do some shopping online. > The way I have it figured, you just saved at least $1200, plus you > are now an authority on waterpump shaft replacement, so you can > talk me through it if mine ever fails. Spend the $1200 on farkle, > tools, a romantic weekend with the wife, etc. > > I'm a little long-winded, but I would encorage you to fix it > yourself and have some fun doing it. > > Ross Lindberg > Fertile, MN > > > [Non-text portions of this message have been removed]

[aphampton628]

The Kawasaki parts diagram shows the water pump drive shaft separate from the balancer shaft but not available separately. Is the water pump drive shaft removable from the balancer shaft? Right or left hand thread? Heat broken shaft to soften thread lock compound at end of shaft? Buy a new balancer shaft assembly to get the water pump drive shaft? All conjecture. Alan

--- In DSN_KLR650@yahoogroups.com, Mike Hansen wrote: > > you have to tear down the engine. the book calls for 7.5hrs. the dealer wanted $900.00 in labor plus parts to perform the job when mine broke. I over tightened the nut stretching the shaft and it broke off. Take a photo and post it. I was able to grind down the face of my impeller to allow more shaft exposure. I tapped the shaft a fe more threads deeper and grinded the nut down to get rid of the bevel and have just straight threads. I used red lock-tite to seal the deal. 3500 miles later and no failure yet. > > -Mike- > > > > > ________________________________ > From: Mike Atkinson > To: DSN_KLR650@yahoogroups.com > Sent: Friday, March 20, 2009 11:30:25 AM > Subject: [DSN_KLR650] Balancer shaft replacement > > > Last fall I cracked the clutch cover on my 2005 and had to replace it. Apparently when I installed the new clutch cover I did not fasten the nut on the water pump correctly. > I noticed when I ran the bike it was overheating with leakage of radiator fluid and upon further inspection noticed a very large crack in the water pump cover. > After removing the water pump cover I noticed a lot of metal shavings in the catch bucket I used to catch the radiator fluid. Sure enough, the impeller was chewed up and the nut that holds it onto the impeller shaft had broken off and was spinning around inside the water pump causing the metal shavings. > My questions are as follows: > 1. Is is a difficult job to replace the impeller shaft myself? I am only a moderately skilled mechanic. > 2. What the "H" could I have done wrong to cause the nut on the impeller shaft to shear off? Did I under/over tighten? > 3. I am thinking of taking the bike to a cycle shop and having them do the repairs and since the impeller shaft will have to be replaced should I go ahead and have the "doohicky" replaced as well? > Thanks guys. > Muddy Shoe Mike "05 KLR" rider > > [Non-text portions of this message have been removed] > > > > > [Non-text portions of this message have been removed] >

[andykisz]

Check out this link. It should help you decide if you are up to the task. http://www.sgtmarty.klr650.net/SgtMarty_impeller_shaft/SgtMarty-Impeller-shaft-repair.html

--- In DSN_KLR650@yahoogroups.com, Mike Atkinson wrote: > > Last fall I cracked the clutch cover on my 2005 and had to replace it. Apparently when I installed the new clutch cover I did not fasten the nut on the water pump correctly. > I noticed when I ran the bike it was overheating with leakage of radiator fluid and upon further inspection noticed a very large crack in the water pump cover. > After removing the water pump cover I noticed a lot of metal shavings in the catch bucket I used to catch the radiator fluid. Sure enough, the impeller was chewed up and the nut that holds it onto the impeller shaft had broken off and was spinning around inside the water pump causing the metal shavings. > My questions are as follows: > 1. Is is a difficult job to replace the impeller shaft myself? I am only a moderately skilled mechanic. > 2. What the "H" could I have done wrong to cause the nut on the impeller shaft to shear off? Did I under/over tighten? > 3. I am thinking of taking the bike to a cycle shop and having them do the repairs and since the impeller shaft will have to be replaced should I go ahead and have the "doohicky" replaced as well? > Thanks guys. > Muddy Shoe Mike "05 KLR" rider > > > > > > [Non-text portions of this message have been removed] >

[aphampton628]

--- In DSN_KLR650@yahoogroups.com, "aphampton628" wrote:

> > The Kawasaki parts diagram shows the water pump drive shaft separate from the balancer shaft but not available separately. > > Is the water pump drive shaft removable from the balancer shaft? Right or left hand thread? Heat broken shaft to soften thread lock compound at end of shaft? Buy a new balancer shaft assembly to get the water pump drive shaft? All conjecture. > > Alan

Has anyone ever removed the water pump shaft from the balancer shaft and if so could it be done without removing the balancer shaft from the engine? Alan

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, "andykisz" wrote:

> > Check out this link. It should help you decide if you are up to the task. > > http://www.sgtmarty.klr650.net/SgtMarty_impeller_shaft/SgtMarty-Impeller-shaft-repair.html > >

Thanks Andy, Wow. what a write up. Sgt Marty is the hero-de-jour. revmaaatin.

[Tumu Rock]

--- In DSN_KLR650@yahoogroups.com, "J. Christopher Krok" wrote:

> > I want to die peacefully in my sleep, like my grandfather. Not yelling and screaming like the people in his car... > > > > Krokko >

Hahahahahahaha!!!!! da Vermonster