klr650 1-2nd gears

[rusty_knott]

I have a 2002 KLR 650 that the rear hub just kind of fell to pieces. It looks as if the entire damper disentegrated and caused the teeth inside the hub to break off which caused the rear sprocket to shift sideways, which caused the sprocket to dig into and eat out a portion of the swing arm. Lucky for me I was not going fast. Now for the bad news. The dealer is saying this was all caused by the rear nut not being tight enough. They are saying the nut is routine maintenance and thus warranty will not cover the damages. This is hard for me to believe. However, it happened and I need to move on one way or another. Can anybody expand on how this rear axle nut got loose with a cotter pin in it(at least loose enough to cause damage) and second, where can I find a used swing arm? By the way the bike only has 4500 miles on it. Thanks for your responses. Rob

[Rick McCauley]

2002 ! Warranty ? Did you get an extended warranty ? Rob, I work in customer service. If I were you, I would call Kawasaki direct. I have to believe they will help you. If your bike is under warranty, I think you have a valid claim. Rick A17 rusty_knott wrote: I have a 2002 KLR 650 that the rear hub just kind of fell to pieces. It looks as if the entire damper disentegrated and caused the teeth inside the hub to break off which caused the rear sprocket to shift sideways, which caused the sprocket to dig into and eat out a portion of the swing arm. Lucky for me I was not going fast. Now for the bad news. The dealer is saying this was all caused by the rear nut not being tight enough. They are saying the nut is routine maintenance and thus warranty will not cover the damages. This is hard for me to believe. However, it happened and I need to move on one way or another. Can anybody expand on how this rear axle nut got loose with a cotter pin in it(at least loose enough to cause damage) and second, where can I find a used swing arm? By the way the bike only has 4500 miles on it. Thanks for your responses. Rob Archive Quicksearch at: http://www.angelfire.com/ut/moab/klr650_data_search.html List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Yahoo! Groups Links --------------------------------- Yahoo! for Good Click here to donate to the Hurricane Katrina relief effort. [Non-text portions of this message have been removed]

[ron criswell]

I don't know if you or someone changed your tire recently and forgot the spacer or put it in the wrong place. This can cause something like that. Ask CA Stu. He had a certain Honda shop in Monticello Utah fix a flat but didn't do the spacer correctly and his hub got screwed up. By the way I don't think the shop paid for the damage. It is best to at least take off the wheel yourself and tighten the chain yourself. A lot of the mechanics are not too familiar with every machine. I have had good mechanics tighten the chain too tight on the KLR mainly because they work on mostly cruisers and sportbikes and are not familiar with long travel suspensions. Criswell

On Wednesday, September 28, 2005, at 07:52 PM, rusty_knott wrote: > I have a 2002 KLR 650 that the rear hub just kind of fell to pieces. > It looks as if the entire damper disentegrated and caused the teeth > inside the hub to break off which caused the rear sprocket to shift > sideways, which caused the sprocket to dig into and eat out a portion > of the swing arm. Lucky for me I was not going fast. Now for the bad > news. The dealer is saying this was all caused by the rear nut not > being tight enough. They are saying the nut is routine maintenance > and thus warranty will not cover the damages. This is hard for me to > believe. However, it happened and I need to move on one way or > another. Can anybody expand on how this rear axle nut got loose with > a cotter pin in it(at least loose enough to cause damage) and second, > where can I find a used swing arm? By the way the bike only has 4500 >

[Chris Krok]

> From: "rusty_knott" > Subject: Rear Hub Fell To Pieces > > I have a 2002 KLR 650 that the rear hub just kind of fell to pieces. > It looks as if the entire damper disentegrated and caused the teeth > inside the hub to break off which caused the rear sprocket to shift > sideways, which caused the sprocket to dig into and eat out a portion > of the swing arm. Lucky for me I was not going fast. Now for the bad > news. The dealer is saying this was all caused by the rear nut not > being tight enough. They are saying the nut is routine maintenance > and thus warranty will not cover the damages. This is hard for me to > believe. However, it happened and I need to move on one way or > another. Can anybody expand on how this rear axle nut got loose with > a cotter pin in it(at least loose enough to cause damage) and second, > where can I find a used swing arm? By the way the bike only has 4500 > miles on it. Thanks for your responses. Rob

That sounds like baloney to me... As you mention, with the cotter pin, the rear nut most certainly is NOT "routine maintenance." It does sound like the inner spacer was missing, though. Have you had the rear tire changed at any time? (Although, usually the sprocket will eat into the swingarm before the other stuff happens.) You'd have to check Ebay for a swingarm. A guy on the MADS list is parting out a KLR as well, so you might want to check there. Krokko -- Dr. J. Christopher Krok Explosion Dynamics Laboratory John Lucas Adaptive Wind Tunnel Caltech MS 205-45, Pasadena, CA 91125

[Chris Krok]

> From: "April Neave & Norm Keller" > Subject: Re: KLR650 1-2nd Gears > > > The only practical possibility would be if a set from another bike might > happen to fit but it would be almost impossible to determine that other > gears would fit. There is no standard for identifying gears across model or > maker lines. > > If you found gears and were able to do the install yourself, it would still > beg the question of whether the expenditure of time and money would be worth > while.

Actually, it can be quite worthwhile if you ride in offroad conditions that require a 14t front sprocket. First and second gear from a KLR600 will swap in directly, although I agree that it's a big project. I would certainly give it a try if I had the opportunity. I think Kurt and some others have done it, and are happy with it. Krokko -- Dr. J. Christopher Krok Explosion Dynamics Laboratory John Lucas Adaptive Wind Tunnel Caltech MS 205-45, Pasadena, CA 91125