Wilsons Sandbox

I dunno. I'd just put a little loc-tite on it and be done. -Jeff Khoury From: "RobertWichert" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Tuesday, May 17, 2011 10:34:35 AM Subject: [DSN_KLR650] Choke Lever Problems - 2007 KLR 650 I replaced my choke lever and messed it up. My old one broke in one of my numerous falls, so I replaced it with a new Kawi part. (Has anybody ever taken their mirrors off before riding off-road to avoid knocking them loose like I do every damned time that I fall?) Back to my choke lever - It now backs out the screw that holds it together, a little bit every time I use it. After a few uses, the screw is loose and I have to tighten it again. If I over tighten it, it's hard to move the lever the first time I use it, but once I cycle it a few times the screw backs out and it gets easier. Eventually the screw is too loose and needs to be over tightened again. I know that I assembled it wrong, but I don't know what I did wrong. It has two wave washers, which is what I suspect I screwed up. The stacking order now is like this: Starting at the handlebar Support Stationary portion Wave washer 1 Wave washer 2 Rotating portion Small flat washer Allen screw The screw may be too long or the wrong one, or it may be missing some sort of internal tubular stop piece (grasping for solutions here) that I have lost. Any ideas out there? Fred? -- Robert P. Wichert P.Eng LEED AP +1 916 966 9060 FAX +1 916 966 9068 =============================================== [Non-text portions of this message have been removed]

--- In DSN_KLR650@yahoogroups.com, RobertWichert wrote:

> > I replaced my choke lever and messed it up. My old one broke in one of > my numerous falls, so I replaced it with a new Kawi part. (Has anybody > ever taken their mirrors off before riding off-road to avoid knocking > them loose like I do every damned time that I fall?)

Robert, Fred used to (maybe still does) sell a mirror isolator that extended the mirror stalk ~1.3862". I made the 'fuzzy view" less fuzzy but mostly it allowed the mirror to bend ~30 degrees after dropping the bike. Mirror isolators coupled with 'bark-buster' lever protectors, I have yet to break/bend a mirror or quadrant switch. I also use the relocated clutch lever mirror perch. How well does it work? Do I fall down? sigh. Yes, I have my fair shares. If Fred still has those mirror isolators, I would be ready for a set for my new to me KLR as well. revmaaatin.

Plus eleven on the use of LocTite... job done. I relocated my mirrors to avoid breaking the left switch housing. The right mirror was relocated off the bike and then used on the left after I broke the left. I used to remove the mirrors and my tool bag every time I'd drop into the trails. Bought a KTM folding mirror. Looks like the OEM round mirror or 1st gen bikes. A bit longer so you can see more than your shoulder. Slightly reduced vibes and it folds down to the bar without tools. Now all I stash at the trail head is the tool bag and maybe a layer of cloths. Mech

--- In DSN_KLR650@yahoogroups.com, RobertWichert wrote: > > I replaced my choke lever and messed it up. My old one broke in one of > my numerous falls, so I replaced it with a new Kawi part. (Has anybody > ever taken their mirrors off before riding off-road to avoid knocking > them loose like I do every damned time that I fall?) > > Back to my choke lever - It now backs out the screw that holds it > together, a little bit every time I use it. After a few uses, the screw > is loose and I have to tighten it again. If I over tighten it, it's > hard to move the lever the first time I use it, but once I cycle it a > few times the screw backs out and it gets easier. Eventually the screw > is too loose and needs to be over tightened again. I know that I > assembled it wrong, but I don't know what I did wrong. It has two wave > washers, which is what I suspect I screwed up. The stacking order now > is like this: > Starting at the handlebar > Support > Stationary portion > Wave washer 1 > Wave washer 2 > Rotating portion > Small flat washer > Allen screw > > The screw may be too long or the wrong one, or it may be missing some > sort of internal tubular stop piece (grasping for solutions here) that I > have lost. > > Any ideas out there? Fred? > > > -- > > > > Robert P. Wichert P.Eng LEED AP > +1 916 966 9060 > FAX +1 916 966 9068 > > > > > > > > > > > > =============================================== >

Robert- Try putting a wave washer on either side of the rotating portion (I assume you mean the lever). I checked http://www.bikebandit.com/1999-kawasaki-klr650-off-road-motorcycle-parts/oem-parts/s/mg11096> and found a little blowup. It shows the support, the stationary portion, a washer, the lever, then the allen screw. It doesn't even show the two wave washers, which seems suspicious. A similar diagram without the numbers is as p. 12-2 of Kawasaki's supplemental manual. Below is a snap from bikebandit (thank you bikebandit), don't know if it will come through to you: The "reference number" (for a '99 anyway) is 46092A, and the part no. 46092-1123, for this assembly. And there's this from the FAQ at http://bigcee.com/klr650faq.html#intake >: "Is there a less-vulnerable choke lever available? "With the choke out on the handlebar, it's possible to break it when you dump the bike. Lister Zach found a short choke cable for the CVK40 from Harley Davidson: Part# 29229-88C, Cable, Carburetor Enrichment. You need to come up with a mounting bracket, but you can check out an installation in the links section. While you're down there, be careful about breaking the plastic choke fitting on the carb. You can get an aluminum one from Stead Engineering." I couldn't find the "installation in the links section" though. -Jamie [Non-text portions of this message have been removed]

Oh. Maybe that's why there are two wave washers. It's working now, but that's worth a try. Thanks Jamie! Robert P. Wichert P.Eng LEED AP +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 5/18/2011 8:35 AM, Flower Jamie wrote: > > Robert- Try putting a wave washer on either side of the rotating > portion (I assume you mean the lever). > I checked > http://www.bikebandit.com/1999-kawasaki-klr650-off-road-motorcycle-parts/oem-parts/s/mg11096> > and found a little blowup. It shows the support, the stationary > portion, a washer, the lever, then the allen screw. It doesn't even > show the two wave washers, which seems suspicious. A similar diagram > without the numbers is as p. 12-2 of Kawasaki's supplemental manual. > Below is a snap from bikebandit (thank you bikebandit), don't know if > it will come through to you: > > The "reference number" (for a '99 anyway) is 46092A, and the part no. > 46092-1123, for this assembly. And there's this from the FAQ at > http://bigcee.com/klr650faq.html#intake >: > "Is there a less-vulnerable choke lever available? > "With the choke out on the handlebar, it's possible to break it when > you dump the bike. Lister Zach found a short choke cable for the CVK40 > from Harley Davidson: Part# 29229-88C, Cable, Carburetor Enrichment. > You need to come up with a mounting bracket, but you can check out an > installation in the links section. While you're down there, be careful > about breaking the plastic choke fitting on the carb. You can get an > aluminum one from Stead Engineering." > I couldn't find the "installation in the links section" though. > -Jamie > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

Sorry my internet has been down until now. You can find the schematic of the choke lever on the Kawasaki site here: https://www.kawasakiepc.com/SSIConverted/2720986_110518_032619_3666.png Fred http://www.arrowheadmotorsports.com From: RobertWichert Sent: Tuesday, May 17, 2011 11:34 AM To: DSN KLR650 Subject: [DSN_KLR650] Choke Lever Problems - 2007 KLR 650 I replaced my choke lever and messed it up. My old one broke in one of my numerous falls, so I replaced it with a new Kawi part. (Has anybody ever taken their mirrors off before riding off-road to avoid knocking them loose like I do every damned time that I fall?) Back to my choke lever - It now backs out the screw that holds it together, a little bit every time I use it. After a few uses, the screw is loose and I have to tighten it again. If I over tighten it, it's hard to move the lever the first time I use it, but once I cycle it a few times the screw backs out and it gets easier. Eventually the screw is too loose and needs to be over tightened again. I know that I assembled it wrong, but I don't know what I did wrong. It has two wave washers, which is what I suspect I screwed up. The stacking order now is like this: Starting at the handlebar Support Stationary portion Wave washer 1 Wave washer 2 Rotating portion Small flat washer Allen screw The screw may be too long or the wrong one, or it may be missing some sort of internal tubular stop piece (grasping for solutions here) that I have lost. Any ideas out there? Fred? -- Robert P. Wichert P.Eng LEED AP +1 916 966 9060 FAX +1 916 966 9068 =============================================== [Non-text portions of this message have been removed]

Those mirror dampers have been on back order for over a year now. I don t look for them anytime soon. There are other solutions for mirror vibrations or for protecting the mirrors from damage. I used to sell the Honda mirrors when they were sold as an assembly from Honda. Honda now sells these mirrors only by individual pieces and have almost doubled the costs. The new model KLR mirrors have a damper built in and these are the ones I am now stocking. If you are wanting to fold your mirrors out of the way when riding off road, there are several options. The folding Enduro Mirrors will allow you to tuck the mirror in behind your handlebar crossbar. Not sure if IMS is still making the gizmo that folds down your stock mirrors but I happen to have a set of those for sale. The other option would be the small plastic mirrors made by Acerbis and others. These have a ball and socket mount and will allow you to hide them fairly well but the view out of these mirrors is not very good. So depending on what you are wanting to do with your mirrors, there are several things you could try. Fred http://www.arrowheadmotorsports.com From: revmaaatin Sent: Tuesday, May 17, 2011 11:17 PM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Re: Choke Lever Problems - 2007 KLR 650

--- In mailto:DSN_KLR650%40yahoogroups.com, RobertWichert wrote: > > I replaced my choke lever and messed it up. My old one broke in one of > my numerous falls, so I replaced it with a new Kawi part. (Has anybody > ever taken their mirrors off before riding off-road to avoid knocking > them loose like I do every damned time that I fall?) Robert, Fred used to (maybe still does) sell a mirror isolator that extended the mirror stalk ~1.3862". I made the 'fuzzy view" less fuzzy but mostly it allowed the mirror to bend ~30 degrees after dropping the bike. Mirror isolators coupled with 'bark-buster' lever protectors, I have yet to break/bend a mirror or quadrant switch. I also use the relocated clutch lever mirror perch. How well does it work? Do I fall down? sigh. Yes, I have my fair shares. If Fred still has those mirror isolators, I would be ready for a set for my new to me KLR as well. revmaaatin. [Non-text portions of this message have been removed]

Installed the new EBC contour rotor on my 2004. They also gave me a set of EBC FA130X. I put them on but haven't tried em yet. Carbon graphite "X" pads blended with Kevlar for leisure / sport use. I like the EBCs pads I have used before. They carry EBCs with the red backing at Cycle Gear or Cycle Trend. I forget the exact compound but they always worked well. I used those places mainly because the last time I bought them, I was near them when I noticed my pads were very low. The new relocation bracket and pads went on without a hitch. Only hassle of course was making sure the speedo drive/hub/fork went together correctly. Isn't the contour front rotor pretty? http://i943.photobucket.com/albums/ad278/halgot1/OTAY/klrcontour002.jpg http://i943.photobucket.com/albums/ad278/halgot1/OTAY/klrcontour001.jpg If you look throught the other pics in the album above, you will see the scenic OTAY MTN near the border. Some great dirt riding southeast of San Diego, Northeast of TJ. There are even mirrors on posts on the bends in the dirt roads so the border patrol doesn't run into each other or you. There is also single track which at night turns into illegal immigration trails. GREAT RIDING AND NOT FAR FROM EITHER JULIAN OR SAN DIEGO EAGLE-MIKE TECH DAYS. Jeffrey #3