s.s. brake line replacement instructions?

[Glen]

a while back i posted about how i thought i had put my countersprocket on the wrong way with the cupped side out and this was causing a rubbing noise from that area of the bike, so it was suggested that the flat side of the sprocket should be placed outwards. i thought this made sense that is until i just read my clymer and it said to mount the countersprocket such that the cupped side was facing out, so according to that i had it right all along. anyone else confused out there. i am just wondering because i am trying to diagnose the reason for the main output shaft bearing blowing out on me. i know it wasn't from a tight chain, because i made sure it was right and checked it often. thanks for the help straightening out my confusion. glenski - motorless in bedeque a14

[James L. Miller Jr.]

There are only 2 bearings on the countershaft, IIRC. The one cage bearing on the far (clutch side) and the big honkin ball/roller bearing on the sprocket side. If you're still having problems with it, I'd say check the other bearing. Failing that being the problem, check the countershaft for true. Mine had been tweaked on the sprocket side and that .0001 wobble failed the whole shebang. A good machinist would be able to diagnose the problem pretty quickly, or at least a good solid surface to put a run out gage on while the motor is turning over. millerized "insomnia makes me wish I could stay up all night"

--- In DSN_klr650@yahoogroups.com, "Glen" wrote: > a while back i posted about how i thought i had put my > countersprocket on the wrong way with the cupped side out and this > was causing a rubbing noise from that area of the bike, so it was > suggested that the flat side of the sprocket should be placed > outwards. i thought this made sense that is until i just read my > clymer and it said to mount the countersprocket such that the cupped > side was facing out, so according to that i had it right all along. > anyone else confused out there. i am just wondering because i am > trying to diagnose the reason for the main output shaft bearing > blowing out on me. i know it wasn't from a tight chain, because i > made sure it was right and checked it often. thanks for the help > straightening out my confusion. > > glenski - motorless in bedeque > a14

[mwl_95623]

I just finished this exercise myself. I replaced a PBI 16 tooth sprocket with my original OEM 15 tooth sprocket. I too was confused. First I checked the manual to see if the cupped side goes in or out; Nothing. Next I checked the online parts diagram at kawasaki.com; No luck. Next I began searching the archives. I found that the Clymer manual indicates cupped side out. Several other sources say cupped side in and flat side out. Others said just the opposite. I wonder if it really even matters. I say this because when I took off my PBI 16 tooth sprocket the numbers were on the inside and I had run it this way for 18K miles without any problems. I decided to install mine cupped side in\flat side out. It really wasn't completely obvious to me which way it should go. Just seemed more logical. If anyone knows for sure, or has a stock bike they could check, I'd really appreciate it for the peace of mind. Thanks! Matt

--- In DSN_klr650@yahoogroups.com, "Glen" wrote: > a while back i posted about how i thought i had put my > countersprocket on the wrong way with the cupped side out and this > was causing a rubbing noise from that area of the bike, so it was > suggested that the flat side of the sprocket should be placed > outwards. i thought this made sense that is until i just read my > clymer and it said to mount the countersprocket such that the cupped > side was facing out, so according to that i had it right all along. > anyone else confused out there. i am just wondering because i am > trying to diagnose the reason for the main output shaft bearing > blowing out on me. i know it wasn't from a tight chain, because i > made sure it was right and checked it often. thanks for the help > straightening out my confusion. > > glenski - motorless in bedeque > a14

[Zachariah Mully]

On Mon, 2004-05-24 at 01:40, mwl_95623 wrote:

> I decided to install mine cupped side in\flat side out. It really > wasn't completely obvious to me which way it should go. Just seemed > more logical. > > If anyone knows for sure, or has a stock bike they could check, I'd > really appreciate it for the peace of mind. Thanks!

I don't know if anybody makes a purely post-95 sprocket, i.e. one that doesn't have the two 8mm holes drilled and tapped in it for the old style sprocket keeper... In any case, on older KLRs, you *have* to install the sprocket with the flat face outwards, and since the sprocket design hasn't changed, I install the sprocket the same way on my A12 as I do on my A5, flat side out. Z DC A5X A12X

[mwl_95623]

--- In DSN_klr650@yahoogroups.com, Zachariah Mully wrote: Thanks for the reply Zach. I apologize about being somewhat anal about this, but do you uset an OEM sprocket? I ask because my aftermarket PBI sprocket was flat on both sides. The only difference was the amount of material that wraps around the output shaft. And like I said in my original post, I used it for 18K miles without any problems. Maybe it really doesn't matter on post-95's? It certainly seems bizzar that Kawasaki doesn't specify. Matt > > I don't know if anybody makes a purely post-95 sprocket, i.e. one that > doesn't have the two 8mm holes drilled and tapped in it for the old > style sprocket keeper... In any case, on older KLRs, you *have* to > install the sprocket with the flat face outwards, and since the sprocket > design hasn't changed, I install the sprocket the same way on my A12 as > I do on my A5, flat side out. > > Z > DC > A5X > A12X

[Zachariah Mully]

On Mon, 2004-05-24 at 13:20, mwl_95623 wrote:

> --- In DSN_klr650@yahoogroups.com, Zachariah Mully wrote: > Thanks for the reply Zach. I apologize about being somewhat anal > about this, but do you uset an OEM sprocket? I ask because my > aftermarket PBI sprocket was flat on both sides. The only difference > was the amount of material that wraps around the output shaft. And > like I said in my original post, I used it for 18K miles without any > problems. Maybe it really doesn't matter on post-95's? It certainly > seems bizzar that Kawasaki doesn't specify. > > Matt

I've never seen a stock sprocket, but I've got a couple of PBI's and a couple from other manufacturers (unmarked from DennisKirk). They all have two flanges on either side, one is wide and flat, the other is more a narrow lip. I put that on the inside. Z DC A5X A12X

[mwl_95623]

Well thanks again Zach, but I need to know about the "stock" sprocket. So if anybody out there knows or cares to take a look at their stock configuration I'd appreciate it. I'd run by the Kawasaki dealership but they're closed on Monday. Matt

--- In DSN_klr650@yahoogroups.com, Zachariah Mully wrote: > > I've never seen a stock sprocket, but I've got a couple of PBI's and a > couple from other manufacturers (unmarked from DennisKirk). They all > have two flanges on either side, one is wide and flat, the other is more > a narrow lip. I put that on the inside. > > Z > DC > A5X > A12X

[mwl_95623]

This thread did not generate much feedback or interest, but I'll post my results anyway. As I said in previous posts there are mixed opinions as to which way the "OEM" sprocket is to be installed. Some say flat side out and some say flat side in. Apparently the Clymer manual (which I don't have) says flat side in. I got one reponse from a lister that just replaced the original equipment and he said flat side in. I went to my local Kawasaki dealer today and the mechanic said flat side out. Two other assistant mechanics (whose opinion I value more by-the-way) said flat side out also. What is a guy supposed to do? Luckily I have a neighbor who just bought a 2004 that I'd been seeeing drive past my house. I figured it was a good opportunity to track him down, introduce myself, and invite him on this weekends ride. That, and take a look at his factory installed OEM sprocket. Guess what? Flat side in!!! It really boggles my mind that this is such a mystery. I suppose most people replace the OEM sprocket with an aftermarket and never look back. Understandable. But geezee, you'd think the Kawasaki mechanics would know. Too bad there wasn't a KLR to look at the dealership. But according to my neighbor with the 2004 they sold TWELVE in one month! Kawasaki would be crazy to discontinue making the KLR before they absolutely have too with these kind of sales figures! Matt P.S. This information might be worthy of inclusion to the FAQ. But than again maybe not. P.S.P.S. When I took off my 16 tooth aftermarket sprocket I had installed it with the numbers facing in. Apparently this is a no no. But I ran it this way for 18K miles without any problems. And I'm still running the original chain with 25K. --- In DSN_klr650@yahoogroups.com, "mwl_95623" wrote: snip

>I need to know about the "stock" sprocket. > So if anybody out there knows or cares to take a look at their

stock

> configuration I'd appreciate it. I'd run by the Kawasaki

dealership

> but they're closed on Monday. > > Matt >

[James L. Miller Jr.]

--- In DSN_klr650@yahoogroups.com, "mwl_95623" wrote: I went to my local Kawasaki dealer today and the mechanic said flat side out. Two other assistant mechanics (whose opinion I value more by-the-way) Probably a big mistake, but we'll let you go on this as you're new General consensus (and I'm sure to be corrected) is that your mechanic will tell you what ever you want to hear. If he said you could install it horizontally, he'd probably mean it, simply because he won't know. KLR's (not owners) are a very niche group, most dealers (at least in the half dozen or so I've talked to) sell few every few years. My local dealer hasn't ordered one for his shop since 2001 (mine) as he imports from out of state if someone want one. Since 2001, he's sold 2. For a mechanic to tell you something about a bike, I'd have to ask him something else about it. He probably just told you what you wanted to hear. As for the assistants?: Training level or experience? Probably not. They can probably tell the difference between a screwdriver and a crescent wrench and that's why they got the job.

> Luckily I have a neighbor who just bought a 2004 that I'd been >seeeing drive past my house. I figured it was a good opportunity to >track him down, introduce myself, and invite him on this weekends >ride. That, and take a look at his factory installed OEM sprocket. >Guess what? Flat side in!!!

Good move. We all need to stick together. Now you have a riding partner for places you wouldn't normally go alone. You also have a combined knowledge of a great bike, as well as spare parts if he's not riding that weekend. (oh, and more tools) [and maybe some daughters?]

> But according to my neighbor with the 2004 they sold > TWELVE in one month! >

Your dealer sold 12 in one month?! Amazing, have you not gotten names and address's/numbers?! Man, your own Posse right next door! You could have your own version of NOAB in your back yard and the longest rider came 5 blocks! COOL! But, my other part of this would be "how many have been back to the dealer for maintenance" since they bought the bike? Have they been exported out or sold "in house"? Are you sure he knows what a KLR is? ("yeah, man. That new Yamaha KLR is pretty cool, dude!") I've run both rubber in, and rubber out, numbers in and numbers out. 14T, 15T, and 16T. Lining up the sprockets (sighting along the chain if nothing else) is all I do and other than a masterlink coming out (and causing a $h!tload of problems) have never had a chain/sprocket problem. I'm just over 22K on my 2001. Lining up the chain would, in my opinion, be the only way to find out if there was any difference. Now, different years, different specs I'm sure. I'm basing my info on a 2001 model year. Your opinion and mileage will vary. millerized

[mwl_95623]

--- In DSN_klr650@yahoogroups.com, "James L. Miller Jr." wrote: snip

> General consensus (and I'm sure to be corrected) is that your > mechanic will tell you what ever you want to hear.

I think you are right on this one. He and I tend to butt heads. When I question him he tends to get very defensive. True story - while I was there a customer called really upset. He had just blown his engine. Apparently someone at the shop told him he didn't need to use filter oil with his NoToil air filter. I'm not sure what actually was said or who was at fault but it was being heatedly discussed. Probably what the shop told him was not to use regular filter oil. I think the customer was a fault here but I can fully understand the communication problems.

>

snip

> > > Your dealer sold 12 in one month?! Amazing, have you not gotten > names and address's/numbers?! Man, your own Posse right next door! > You could have your own version of NOAB in your back yard and the > longest rider came 5 blocks! COOL! But, my other part of this would > be "how many have been back to the dealer for maintenance" since they > bought the bike? Have they been exported out or sold "in house"?

Eleven in-house and one exported 40 miles away. That posse thing could be right. Just this morning less than a mile from my house a brand spankin new 2004 passed. We took the same route for a bit till he turned into an industrial section. If it's who I think it is he works at a very reputable independant Toyota shop. Gota love having real mechanics along for a ride!

> Are you sure he knows what a KLR is? >

Yep. This is KLR country.

> I've run both rubber in, and rubber out, numbers in and numbers out. > 14T, 15T, and 16T. Lining up the sprockets (sighting along the chain > if nothing else) is all I do and other than a masterlink coming out > (and causing a $h!tload of problems) have never had a chain/sprocket > problem. I'm just over 22K on my 2001. Lining up the chain would, > in my opinion, be the only way to find out if there was any > difference.

Very good advice; Lining up the chain. Matt