'08-'09 klr parts wanted

[revmaaatin]

This has been a 'week' = the past 7-8 days of bike maintenace. Back in June, I blew up a chain and a rear sprocket; while waiting to be rescued by a Ford truck, I was feasted on my the state bird of South Dakota. There was a jillion of them 'feasters'. The good news, bad news: I had the parts to replace the chain and sprockets sitting on my bench, but my schedule buried me in other chores, cough, and I have a 2d KLR I can ride. smile. So I was not hurried to do the repair. Last week was the time. I am greateful to have a small shop space--and with a concrete floor. The downside, most of the time it is like trying to get dressed in a dark broom closet, but I make it work. Get all set up, can't find the grinder stone for the drill to grind off the riveted chain--trying to avoid pulling the swing arm. Borrow a hand grinder from the local blacksmith, drop the chain, and pull out the new chain. Ooops. Riveted 108 link chain for the 46/14 combination. Yeah, now I remember-- Fred--rivet that up for me, OK? Yeah, riveted up tighter than a Monday tick on Saturday. Get to pull the swing arm anyway. sigh. might as well grease the bushings. What took an hour, start to finish, on a previous chain swap w/o the bearing lube, is now taking hours; and them 'feasters' are eating me alive. Call up the DEET!!!! Finally, something besides mosquoties eating me. This chain replacement is the 2d chain I have replaced on this new to me bike (last May 08) purchased in Dallas, TX. It now has 14K more miles and getting its second chain. The first chain replacement I did was after the trip from Dallas, Tx where it shed over 1/2 of it rollers. I replaced those drive components with new sprockets and a riveted OEM chain that I bought as a USMC takeoff chain. At 14K smiles on the OEM chain, the link I cut off was completly devoid of grease. That was a surprise. Not to mention that the teeth all but disappeared from the rear sprocket. More on that later. What was puzzling to me was that in the process of lubing the UNILINK bearings, I discovered there were two bearing that were not centered, one so much so, the dust seal would not seat 'flush'. I discovered this with a careful cleaning of every seal--and it also revealed the seals do take some beatings while keeping out the dirt and water--which is worth the inspeciton. I will replace some of those seals on the next swingarm lube. Fixed the non-cnetered bearing by centering/driving the bearing back with a socket and block of wood to support the unilink. Swingarm bearing were properly installed. Then of course, while working in the failing light, I once again ponder why God has not given us a third hand that would be so handy while doing KLR maintenace over a fat little belly; while pondering this failure of nature/creation, I misrouted the chain. Off comes the swing arm. Reroute the chain. mo-better. From across the street, I have attracted the audiance of one, my friend Gary that is continually amused at wataching me stand on my head and holding the flashlight in my teeth. I tell him that it is the antics of the aging kilerista, used only to attract the attention of unsuspecting mechanics--and to solicit red-blooded help to feed the misquoites.... The 3rd and forth hand were real handy for alignig the swing arm, and the unilink bolts. Thanks Gary. Gary: code for "he who sees in the dark" rev: code for "he who does not see in the dark" Installed the wheel. Misrouted the chain, again. Can't get it back over the chain guard. Off comes the wheel, Gary: "How do you ever do this by yourself?" Is he really talking to me? Yeah, afraid so. Wheel installed, we call it a day, well, a night. It is just to miserable to keep feeding the misquotes by flashlight. more later. A lot more. I get this one healed, and the other KLR swallows a bug.... revmaatin.

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote:

> > This has been a 'week' = the past 7-8 days of bike maintenace.

SNIP

> more later. > A lot more. > I get this one healed, and the other KLR swallows a bug.... > revmaatin. >

the following morning is Friday, I/we pushed the kids out the door--and went back to the garage. The blue 98 KLR is still there, loosely put together. The annoying thing in this equation, I was in Rapid City, SD the weekend before burying a man--his wedding, etal, and took my Progressive Shock to have the N2 serviced. It was suggested that the shocks damping setting was not working because it was out of n2. Jeff Saline introduced me to a man that rebuilds forks/shocks for a living and he could service the n2 and resurrect the damping positions--no dice. It took a small squirt of n2/150psi but the the 5-position damping turns freely. shrug. I am open to suggestions--I think it is broke. Back to the garage: I enlist the help of my lovely assistant, the star of the his show--'the bride is right' and show her which bolt we are going to hold and torque. In a matter of 15m22s I think we got the bike all buttoned up and pushed out in the open and read to roar. Chug. Chug. Chug. Chug. Chug. Chug. hmmmm. Chug. Chug.Chug.Chug.Chug.Chug.Chug. let the starter cool down. Chug.Chug.Chug.Chug.Chug.Chug.Chug. let the starter cool down again. grrrr. I did not expect to to be 60+ days without riding--and did not Seafoam the fuel. Chug.Chug.Chug.Chug.Chug.Chug.Chug. bang, start, idles fine. What is that all about? Let it idle, gear up and do a short two block test ride, back up on blocks. Give it look see, and then head out for two of the four paved curves in the entire county located about 2 miles North. All is well, and I return home. This bike is equipped with a 16/46 and has D607's. What a ride. Sunday I leave for the most distant church of my 3-church circuit aboard the blue-iron-horse. All this is just as the sun is moving above the horizon and the temp is ~57F. Passing Holabird, SD--best known for only receiving 1/4 inch rain during the 40 day flood, the sunflowers were absolutely bursting out loud, screaming YELLOW at the top of their seed pods. This phenomenon usually only last a few days, and sometimes it seems only hours before the bright leaves on the sunflower heads fall to the ground. I was smug as bug, heated grips on HIGH and loving it. The parishioners, just shake their head. Of course there is one, "My boy would ride on a day like this without a jacket or helmet--and he would NEVER wear a balaclava. Yeah, what ever. smile. Is he riding today, or just posing? Dumb look--looking at me. Thought so. Posing. What a day. Went to church 3 times, and got paid to do it on a motorcycle. What a country. What a motorcycle. revmaaatin.

[thewildmanrides650]

I love your storys rev wish my son would ride with me.just wondering if anyone has seen a 2010 klr yet i hope they make a green one?

> > > > This has been a 'week' = the past 7-8 days of bike maintenace. > > SNIP > > > more later. > > A lot more. > > I get this one healed, and the other KLR swallows a bug.... > > revmaatin. > > > > the following morning is Friday, I/we pushed the kids out the door--and went back to the garage. The blue 98 KLR is still there, loosely put together. > > The annoying thing in this equation, I was in Rapid City, SD the weekend before burying a man--his wedding, etal, and took my Progressive Shock to have the N2 serviced. It was suggested that the shocks damping setting was not working because it was out of n2. Jeff Saline introduced me to a man that rebuilds forks/shocks for a living and he could service the n2 and resurrect the damping positions--no dice. It took a small squirt of n2/150psi but the the 5-position damping turns freely. shrug. > I am open to suggestions--I think it is broke. > > Back to the garage: > > I enlist the help of my lovely assistant, the star of the his show--'the bride is right' and show her which bolt we are going to hold and torque. In a matter of 15m22s I think we got the bike all buttoned up and pushed out in the open and read to roar. > > Chug. Chug. Chug. Chug. Chug. Chug. > hmmmm. > Chug. Chug.Chug.Chug.Chug.Chug.Chug. > let the starter cool down. > Chug.Chug.Chug.Chug.Chug.Chug.Chug. > let the starter cool down again. > grrrr. I did not expect to to be 60+ days without riding--and did not Seafoam the fuel. > Chug.Chug.Chug.Chug.Chug.Chug.Chug. bang, start, idles fine. > What is that all about? > > Let it idle, gear up and do a short two block test ride, back up on blocks. Give it look see, and then head out for two of the four paved curves in the entire county located about 2 miles North. All is well, and I return home. This bike is equipped with a 16/46 and has D607's. What a ride. > > Sunday I leave for the most distant church of my 3-church circuit aboard the blue-iron-horse. All this is just as the sun is moving above the horizon and the temp is ~57F. Passing Holabird, SD--best known for only receiving 1/4 inch rain during the 40 day flood, the sunflowers were absolutely bursting out loud, screaming YELLOW at the top of their seed pods. This phenomenon usually only last a few days, and sometimes it seems only hours before the bright leaves on the sunflower heads fall to the ground. > > I was smug as bug, heated grips on HIGH and loving it. > The parishioners, just shake their head. > Of course there is one, "My boy would ride on a day like this without a jacket or helmet--and he would NEVER wear a balaclava. > Yeah, what ever. smile. > Is he riding today, or just posing? > Dumb look--looking at me. > Thought so. Posing. > > What a day. Went to church 3 times, and got paid to do it on a motorcycle. > What a country. > What a motorcycle. > > revmaaatin. >

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote:

> > --- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote: > > > > This has been a 'week' = the past 7-8 days of bike maintenance. > > SNIP > > > more later. > > A lot more. > > I get this one healed, and the other KLR swallows a bug.... > > revmaatin. > > >

The short version: My KLR swallowed a bug. I fixed it The Long version: Monday dawned a beautiful day and the wx changes have given me a headache that only a KLR can cure--well, a KLR and 3 doses of Tylenol that just barely took the edge off. The kids rumble into the house after school, and I suggest a KLR ride--my 13 y/o son: 'yeah, maybe, lots of homework.' I go to prep the bikes and the boy is doing algebra--by the bucket full. We are finally able to launch after supper, and head east down some slightly improved roads and not so slightly improved roads. We pause some 15 miles East at a friends house with his new-to-him race car--and I suggest that I drop off a Honda 80 for his 13 y/o--as he has not learned to ride a bike with a clutch yet. It at least has both the boys attention--someone to ride with besides 'old' people. As we leave, I notice a slight hesitation when I tried to roost the gravel. hmmm. Eastward we travel another 10 miles stretched into 15 miles of roads where they have farmed the ground all the way to the edges of the road/trail. Here is a prime place to get tattooed by a deer, pheasant or even a badger. The corn is high, and the lateral visibility is low. We are traveling down a corn canyon, vigilant for a scatter-brain deer that will win bonus points for knocking you off your bike. or so it seems. We arrive at the DQ for ice cream--and I take notice that the teeny boppers are taking an unusual interest in my boy--just the ice cream please, 'yeah he is a babe magnet' and we retreat to our KLR's and our just desserts--as the sun is reaching the horizon. Nothing better than a KLR and a DQ cone. Well, maybe a Subway sandwich packed at noon and watching the sunset over the Rockies. That is pretty special as well. Subway is my go-to for trail meals. Buy a foot long at noon (if able) and pack the other 1/2 for supper. Not the prescription for every-day, but it often works well. KLR's and eating--does it get any better? Point the bikes West, and the sun has completely disappeared. We have talked about how we should stagger ourselves, and how the wind drift affects the dust for the trailing bike. My bike has been running fine for about 30 miles, sun is setting and it begins a faint surge-- "Is it the dreaded night-noise" that effect that you can hear strange sounds at night that might or might not be there? Airplanes/helicopters are notorious for having night noise--due largely to sensory deprivation. You can't see as much and you ears hear more clearly--and sometimes hear things that don't exist. Surge. Stumble. Drop in RPM. Ah. no. This is not night noise-- this is a dying KLR. My KLR. Yes Virgina, I should have packed the full tool kit. The full tool kit has the allen wrenches--which I would like to have right about, now. Miles and miles, 1000's of miles, and hardly ever a need for a tool. We are going for ice cream--how bad can it be? Like the ghost of Christmas past, I see myself pushing the bike, again. But--it will hold 3K rpms, not much more. so, I press on. I futz with the petcock--off, on, reserve. No affect. We make it to a cross road and I use Sam's head light to see if I am loosing fuel. No. Idles fine. Stumbles on throttle increase. hmmm. Got to be fuel starvation. I hear the recent carb discussions of the Two-Jeff's and try to remember as much as I can. Bike is holding it own at about 35/40 mph, will take a chance and see if it will take me home. It does. Good horse--very good horse. In the safety of my dimly lit garage, I do a carb drain--check for sediment, water. nothing. Take it for a ride. nothing. Bogs on acceleration. I do a carb drain again. nothing. Still bogs on acceleration. I do a bowl flush to see if the fuel is flowing buy leaving the drain open and cranking the bike. It is--not like a lot of fuel flow, but enough. I eyeball the fuel volume in the tank--nearly to the top of the first fuel straw, so treat it for two gallons of gas with sea foam and take it for a ride to flow the treated fuel into the carb and then will park it for the night. Still bogging on acceleration. Tuesday is a busy day--so the seafoam is soaking. Wednesday--back to the bike. Feels like/seems like it is not getting fuel. I've had a consultation with Jeff Saline, and we agree that it sounds like it is not getting fuel--and discuss what it could be and where to start. Leaves a few options: Fuel restricted at the needle valve Fuel restriced at the petcock Bad vacuum line to the petcock Collapsed fuel line Clogged main jet I decided to check the really easy things first. Pulled the fuel line: flowed easily. Blew air into the fuel line while attached to the carb and an empty fuel bowl--air entered carb easily. Hooked up the fuel line, put the carb end into a can, cranked the bike and watched the fuel flow. It was a gusher--so the petcock and vaccum line are good to go. Got to be in the carb. and I am thinking main jet. The ride after the seafoam treatment included 'choking it' at the point of bogging down. Immediate improvement. and I am now pretty certain--main jet. I disconnected the choke lever at the handle bar, removed the plate on the right side of the carb that holds the throttle cables and disconnected the t. cables from the carb. For ease of mind, I also removed the left bracket that hold the starter soloniod so that the carb would turn more easily. Loosened the two clamps at the carb and rotated the carb to expose the bottom. Float bowl screws came out easily, the fuel bowl is 'clean' and the main jet is easily accessible. The main jet was removed and observation through a MK1, zero power eye ball, the end of the main jet looks blocked. Viewed through a 10X Lupe--it is 1/2 blocked with what looks like fiber. I select a hat pin to collect the 'chunk' and am composing the obituary for this thing--it appears to be a piece of insect wing. It has cork-screwed into the main jet and is now the bane of my life. I have previously selected a white napkin (of the finest Walmart variety) to capture this offending particle--so that I might share the picture with you-- and as I place it on the napkin, the internal pressures of the cork-screwed bug-wing unwind and off it goes to Murphysville. The good news, I still had a death grip on the main jet and the relatives of that dead bug will have to pry my dead cold fingers loose to get it. I spray out the jet with carb cleaner (wearing nitrile gloves) and inspect the rest of the carb with a flashlight and mirror. No more bug parts that I can see. I hope they have not found their way into other passages. Install the jet, reverse the disassemble. and push the starter button. Nice start, smooth idle, clean acceleration without load. Looking good. Let it warm up a touch, grab a jacket, helmet, boots and gloves and point the bike out the garage. first gear acceleration--I knew immediately we we in the money. Out to the highway--and pointed south, clear the city limits and we let her eat. Very very nice. WOT through all 6 gears. (a guy can dream, can't he) As good or better than ever. What is of particular interest to me, is how did a bug part get into the fuel. The straw-screens are in place--leading me to belive that the bug entered through the vent lines. any thoughts on that? Made me wonder if the vent lines might benefit from a 'fuel filter' to keep the bugs out. Nice to have the bikes back and 100% operational/running and ready for the next campaign. Be it 100 miles or a 1000. Thinking back to the two totally unrelated failures: the chain/sprocket and the clogged main jet: both gave signs of pending trouble. Both gave an invitation to stop and investigate. Ignoring those invitations is often at great peril and price. Our bikes will often give a gentle invitation before demanding a full blown inspection--and reading about others story, "there I was" in Timbuctu, NY and.... and it is here at DSN that has given me incredible insights into where to look first. Thanks to all who share. Ah, it is so much nicer to be broke down in the garage than feeding the hordes of hungry misquotes out on the trail. This summer, I have tired both. I like the garage solution, mo-better But, a Subway sandwich trailside, might make it a little easier to bear. Presently, two beasties are trailer borne--awaiting a Monday departure for some intense dual sporting. Film at 11. revmaaatin. don't taze me bro'--I sometimes have to trailer in due to other ministry requirments. smile.

[Monty]

<> ____________________________________________________________________________________________ revmaaation, You're a great story teller. Fun way to start the day. Got me excited to take a ride after reading the tale. Just hope the bugs stay where bugs belong. On the face shield! Have a great Labor Day weekend everyone! Monty "ride safe and may all roads lead to adventure" [Non-text portions of this message have been removed]

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, "thewildmanrides650" wrote:

> > I love your storys rev wish my son would ride with me.just wondering if anyone has seen a 2010 klr yet i hope they make a green one?

Wildman, Thanks. IRT to the 2010, I have not seen one, nor the literature for it either. I would interesting to know just how much damage has been happening to the farings/plastics on 08+. From the campaigners viewpoint, the tupperwar pre-o8's still have my vote-- revmaaatin.

[n9udl]

I have almost 4000 miles on my '08. I installed the HT PD Nerf Bars with engine guard, because I knew that, as a newb, I might be crash prone. [:D] Since then, I dropped the bike (gently?) three times on the Alpine Loop and once on trails in northern Wisconsin. So far, the only "damage" is a scrape to the sticker on the left side cover. I have no idea how much damage would have been done without the nerf bars. -Tom

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote: > I would interesting to know just how much damage has been happening to the farings/plastics on 08+. > > From the campaigners viewpoint, the tupperwar pre-o8's still have my vote-- > > revmaaatin. > [Non-text portions of this message have been removed]

[Rick McCauley]

I agree. I think the 08+ models are too pretty. I wish they would go back to the pre- 08 look. Of course they should keep the suspension upgrades, but go back to the longer travel of the pre- 08. I like the tall dirt bike look of the older models. I have a 35" inseam. And as long as were at it, stick the Versys motor in the old frame. And tune it so it pulls like a tractor. I have a 03, and I will not upgrade past an 07, unless my demands are met Rick A17

--- On Sat, 9/5/09, revmaaatin wrote: From: revmaaatin Subject: [DSN_KLR650] Re: m;y sick KLR's story To: DSN_KLR650@yahoogroups.com Date: Saturday, September 5, 2009, 10:25 AM --- In DSN_KLR650@yahoogro ups.com, "thewildmanrides650 " wrote: > > I love your storys rev wish my son would ride with me.just wondering if anyone has seen a 2010 klr yet i hope they make a green one? Wildman, Thanks. IRT to the 2010, I have not seen one, nor the literature for it either. I would interesting to know just how much damage has been happening to the farings/plastics on 08+. From the campaigners viewpoint, the tupperwar pre-o8's still have my vote-- revmaaatin. [Non-text portions of this message have been removed]

[roncriswell@sbcglobal.net]

What an idea. Me and a friend who does this sort of thing have discussed putting a Versey engine in my 52,000 miler when the engine goes bad. I don't think the pretty plastic on the new ones would survive trail misadventures. I too may go the KLX 250 route. I wish it was a 450. Criswell Sent from my iPhone

On Sep 8, 2009, at 10:13 AM, Rick McCauley wrote: > I agree. I think the 08+ models are too pretty. I wish they would go > back to the pre- 08 look. Of course they should keep the suspension > upgrades, but go back to the longer travel of the pre- 08. I like > the tall dirt bike look of the older models. I have a 35" inseam. > And as long as were at it, stick the Versys motor in the old frame. > And tune it so it pulls like a tractor. > > I have a 03, and I will not upgrade past an 07, unless my demands > are met > > Rick > A17 > > --- On Sat, 9/5/09, revmaaatin wrote: > > From: revmaaatin > Subject: [DSN_KLR650] Re: m;y sick KLR's story > To: DSN_KLR650@yahoogroups.com > Date: Saturday, September 5, 2009, 10:25 AM > > > > --- In DSN_KLR650@yahoogro ups.com, "thewildmanrides650 " > wrote: > > > > I love your storys rev wish my son would ride with me.just > wondering if anyone has seen a 2010 klr yet i hope they make a green > one? > > Wildman, > > Thanks. > > IRT to the 2010, > I have not seen one, nor the literature for it either. > > I would interesting to know just how much damage has been happening > to the farings/plastics on 08+. > > From the campaigners viewpoint, the tupperwar pre-o8's still have my > vote-- > > revmaaatin. > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

[gavinmacfarlane]

Have a look at this picture out of an Aussie ADVRide report, one guy over here has a very modified Versys:- http://www.advrider.com/forums/attachment.php?attachmentid=214655&stc=1&d=1251713156 Gavin A18 Broadford Victoria Australia

--- In DSN_KLR650@yahoogroups.com, "roncriswell@..." wrote: > > What an idea. Me and a friend who does this sort of thing have > discussed putting a Versey engine in my 52,000 miler when the engine > goes bad. I don't think the pretty plastic on the new ones would > survive trail misadventures. I too > may go the KLX 250 route. I wish it was a 450. > > Criswell > > Sent from my iPhone > > On Sep 8, 2009, at 10:13 AM, Rick McCauley wrote: > > > I agree. I think the 08+ models are too pretty. I wish they would go > > back to the pre- 08 look. Of course they should keep the suspension > > upgrades, but go back to the longer travel of the pre- 08. I like > > the tall dirt bike look of the older models. I have a 35" inseam. > > And as long as were at it, stick the Versys motor in the old frame. > > And tune it so it pulls like a tractor. > > > > I have a 03, and I will not upgrade past an 07, unless my demands > > are met > > > > Rick > > A17 > > > > --- On Sat, 9/5/09, revmaaatin wrote: > > > > From: revmaaatin > > Subject: [DSN_KLR650] Re: m;y sick KLR's story > > To: DSN_KLR650@yahoogroups.com > > Date: Saturday, September 5, 2009, 10:25 AM > > > > > > > > --- In DSN_KLR650@yahoogro ups.com, "thewildmanrides650 " > > wrote: > > > > > > I love your storys rev wish my son would ride with me.just > > wondering if anyone has seen a 2010 klr yet i hope they make a green > > one? > > > > Wildman, > > > > Thanks. > > > > IRT to the 2010, > > I have not seen one, nor the literature for it either. > > > > I would interesting to know just how much damage has been happening > > to the farings/plastics on 08+. > > > > From the campaigners viewpoint, the tupperwar pre-o8's still have my > > vote-- > > > > revmaaatin. > > > > [Non-text portions of this message have been removed] > > > > > > > [Non-text portions of this message have been removed] >