atgatt - damn dumb design - redux

[Jeffrey]

Zerk fittings are a waste of time and effort. Many people have had problems installing them; often they install so cannot get at with grease gun or a rock will break one off. The simple solution is to use a car floor jack. Knock out the 2 shafts that require lubing; one at a time. Knock them out with similar but slightly smaller shafts. And leave the driver shafts half in there temporarily to keep things aligned.Clean up and grease the hell out of the shafts you knocked out; pump grease into the voids. Use waterproof grease; I like blue marine grease. THIS IS GOOD FOR 10 YEARS AND TAKES 1 HOUR. Unless you use your KLR as a submarine, you will only have to do this 2 times in the life of your KLR. KEEP IT SIMPLE; WHY MAKE LIFE DIFFICULT? Jeffrey #3

[spike55_bmw]

DING, DING, DING! After loosening the swing arm bolt, the engine mounting bolt, and using a block of wood and mallet the frame opened up enough to get the 3-lobe lever out / in. I had thought that the sleeve had rusted up in place but I really had a major "pinch" going on and that was the problem. This didn't happen before, when I disassembled / reassembled twice before, so it caught me off guard. I guess the zerk idea is OK and I just need to "split the frame" more completely in the future when doing that job again. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, "mechanizeinc" wrote: > > If you loosen the engine bolt, it lets the frame spread a little bit and the spacer will come out. But it\f it's clean and you've serviced the bearings, you could reassemble now. > > Mech > > --- In DSN_KLR650@yahoogroups.com, "spike55_bmw" wrote: > > > > In 2009, I installed zerk fittings at all of the appropriate places on the rear swing arm / suspension. I've kept up a routine greasing program since then. > > > > Last night, I started taking everything apart to replace two fittings that I "smeared" on a rock in early May. All went well until the lower frame bolt area and the 3-lobed lever. Although I had a film of grease on the bolt in 2009, it was "powder coated" from corrosion but it came out. My problem is now with the bearing sleeve. It is stuck in the frame. The routine greasing has kept the bearing in the 3-lobed lever free-moving around the sleeve but.... > > > > I guess I'll have to leave it soak in WD-40 and use a punch pin to get it to move but what a damn dumb design. Once things are out, I guess I could load up the frame tube with grease upon reassembly but wouldn't that allow the hard steel sleeve to start to rotate in the soft metal frame, thereby becoming the unintentional and substandard bearing? > > > > ATGATT - All of The Grease All of The Time didn't work for me. Seems like one should remove this lower bolt / sleeve / 3-lobed lever assembly every year. No matter what you do, it corrodes in this east coast climate. > > > > Don R100, A6F > > >