nklr: black boxes

[Guest]

Gents, Am getting back into biking after an absence of 20 years. Just bought a 2002 KLR with 5000 km on it and am very excited and anxious to drive !!! Damn Canadian winters!! My last bike was a Bultaco 360 Frontera, back in my dirt ridding days. Doubt that I am in good enought shape at 50+ to attempt the same style of ridding but am sure I'll have fun with the KLR!!! My question is, should I replace the "doohickey" cam tensioner lever I keep reading about? especially from a preventative mtce. point of view? If so who should I order it from and what else do I need to get the job done? Also, have noticed some black sooty residue on the left side of the engine on the cooling fins, not much, but wondered if anyone could explain the origin? Thanks in advance for any information, you guys have a great group! The best I have seem on the Web, hope I can contribute something in future! .

[mtc46jw2000]

Gents, just bought a 2002 KLR with 5000 km on at Xmas and am really exicted and can't wait for spring! Being an old dirt bike rider of years ago (Bultaco 360 Frontera) know I won't be doing anything really wild with the bike, probably because of my "advanced" age of 52, non the less, want to be prepared for a long reliable summer. couple of questions if you don't mind; 1. Should I do this MOD as part of a good preventive mtce program? 2. IF so, who should I buy from? and what else do I need? One last question if you guys don,t mind. I notice some what looks like blow-by or sooty residue on the left side of cylinder head, not much but is there on an otherwise mint bike. Any ideas as to what it comes from. Thanks for your reply in advance, you certainly have a great group here and well moderated. Best I have seen on the internet. Hope I can contribute something in the future!

[guymanbro]

--- In DSN_klr650@yahoogroups.com, "mtc46jw2000 " wrote:

> 1. Should I do this MOD as part of a good preventive mtce program?

If'n you're talking about the infamous doohickey...it boils down to this: Those who have seen the failure will tell you change it. Those who have not prefer to live in an "ignorance is bliss" world. You have to decide whether or not it's worth it for your machine. I have had 2 doohickeys fail... I believe in the mod.

> 2. IF so, who should I buy from? and what else do I need?

Jake Jakeman (sagebrush machine shop)as the original and still the cheapest aftermarket doohickey. Zen/Eagle Machine also have the part available. You'll need a rotor holder wrench and a rotor puller bolt and a new rotor bolt.

> > One last question if you guys don,t mind. I notice some what looks > like blow-by or sooty residue on the left side of cylinder head,

not much but is there on an otherwise mint bike. Any ideas as to what it comes from. Could be from the connection of the header pipe and cylinder head. There is a copper crush washer in there that might need replacing...or the bolts might have backed out a little. dat brooklyn bum

>

[Glen Harness]

> have to decide whether or not it's worth it for your machine. I have > had 2 doohickeys fail... I believe in the mod.

Just out of curiosity, did you report the failure to Kawasaki and the Consumer Product Safety Commission? I have a theory that a recall notice hasn't been issued on this because no one has informed the CPSC when they replace their failed doohickey, and without that prompt, KHI won't be pressured to fix it. Glen

[Ron Crandell]

--- In DSN_klr650@yahoogroups.com, "mtc46jw2000 " wrote:

> My question is, should I replace the "doohickey" cam tensioner

lever

> I keep reading about? especially from a preventative mtce. point of > view? If so who should I order it from and what else do I need to > get the job done?

YES!!! I replaced mine on my '02 at 6,000 miles, and although it wasn't broken, it wasn't doing its job. I would highley recommend doing this just for the peace of mind. Contact either Jake or Fred for all the tools you'll need. (I used Jake's part, and got the tools from Fred...)

> > Also, have noticed some black sooty residue on the left side of the > engine on the cooling fins, not much, but wondered if anyone could > explain the origin?

I would guess that you have some sort of leak at the exhaust, maybe at the exhaust location itself, or a small crack in the pipe?? That's where I'd start..

> > Thanks in advance for any information, you guys have a great

group!

> The best I have seem on the Web, hope I can contribute something in > future!

You're right there!! Enjoy the bike, and stay in touch!! Ron in St. Cloud, MN.

> > > > .

[Glen Harness]

> If'n you're talking about the infamous doohickey...it boils down to > this: Those who have seen the failure will tell you change it. Those > who have not prefer to live in an "ignorance is bliss" world. You > have to decide whether or not it's worth it for your machine. I have > had 2 doohickeys fail... I believe in the mod.

Actually, my previous message should have asked if you'd reported it to the National Highway Traffic Safety Administration at http://www.nhtsa.dot.gov/ivoq/oscripts/IVOQ/VOQ/voq1.cfm . Heck, they issued a recall order for some Buell motorcycles just because the side stand could break, which "could cause the motorcycle to fall, increasing the risk of injury." That was for a total of 371 bikes. That alone tells me no one is reporting the doohickey failure to the proper governmental authorities, else this would already have been fixed. How about everyone who's ever had a doohickey failure go to the above web site and fill out the form? Glen

[Devon Jarvis]

> > I wonder if any of the outer edge computer guys has learned of a way to defeat this? > > jim_ama585601

That will happen about three days after they're installed in everyone's cars. The more enterprising souls will modify instead of disabling, so the black box says they're somewhere where they weren't. Instant alibi. And since it will be easier to download somebody's location than doing real detective work, people will trust what the system tells them. Devon