starter interlock

[sh8knj8kster]

Trying to make a long story short=:-)...if you'll recall, I had an oil leak at the rubber plug which covers the balance shaft adjustment bolt. Recently I made the adjustment (at 8 K miles) and afterwards it leaked oil, and more than I care for So I bought a left outer cover gasket, the new o-ring and a new rubber plug as the OE plug came off on the road somewhere, after the leaking oil made the plug swell and it fell off I finally got around last week to pull the cover so I could get at and replace the faulty o-ring. My KLR is an 08' with approx. 8 K miles So I pull the cover, take a few pics and shoot Jeff Saline an email so he could look over the photos and offer me some advice (thanks Jeff) Jeff noticed one of four washers for the two starter gear shafts was apparently missing and he thought it might have flipped off behind the rotor when I pulled the outer cover I have the doo kit and have been meaning to replace the oe doo with the Eagle Mike doo but I didn't want to do it this time around...time contraints, I was getting the KLR ready for an RTE this weekend (which I subsequently missed=:-( Anyways, It would be prudent to pull the rotor to look for the missing washer, and do the doo at the same time. I'd phoned my local dealer to see if they had one of these washers in stock, they don't so I'm taking it down to do the doo while I wait for the part, in the event the washer never made it on when the motor was originally assembled I came up with that theory when I took a good long hard look at the hole in the inner cover where the lower starter gear butts agasinst it, where the washer is missing. My conclusion?, the surface where the washer would sit looks traumatized, unlike the other 3 alloy surfaces where there was a washer (part# 92022) here's a pic of the inner case hole, where I didn't find the washer http://tinyurl.com/yzq55cl I'm wondering...has anyone else on this list come across one of these washers missing when you did your doo mod? Just curious... Jake Reddick Fla. Many people claim coffee inspires them, but, as everybody knows, coffee only makes boring people even more boring. -- Honore de Balzac

[spike55_bmw]

What often happens with those small inconspicuous washers, as well as, the large one behind the big starter gear round the rotor is that they sometimes stick to the back of the gear, sometimes not. Because of this inconsistency, the washers might stay on the case (becuase you're removing the gears and shafts together)and then fall into the lower side case when you're not looking or if they are stuck to the gears, they can fall off later, in transit, or where you have the gears sitting, or they actually stay with the gears - one never knows. You really have to pay attention to those washers or they don't get back where they belong. The rotor is a big permanent magnet and can pick up any lose parts but there is an oil drain passage way at the bottom of the sidecase. If you have a magnetic drain plug, a washer might be there. If you have a small magnetic wand, you can 'fish' it through that passage way and maybe find it. I've gone that route when the rotor key dropped out of the slot when I was putting it back together. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, "sh8knj8kster" wrote: > > Trying to make a long story short=:-)...if you'll recall, I had an oil leak at the rubber plug which covers the balance shaft adjustment bolt. Recently I made the adjustment (at 8 K miles) and afterwards it leaked oil, and more than I care for > > > So I bought a left outer cover gasket, the new o-ring and a new rubber plug as the OE plug came off on the road somewhere, after the leaking oil made the plug swell and it fell off > > > I finally got around last week to pull the cover so I could get at and replace the faulty o-ring. My KLR is an 08' with approx. 8 K miles > > > So I pull the cover, take a few pics and shoot Jeff Saline an email so he could look over the photos and offer me some advice (thanks Jeff) > > > Jeff noticed one of four washers for the two starter gear shafts was apparently missing and he thought it might have flipped off behind the rotor when I pulled the outer cover > > > I have the doo kit and have been meaning to replace the oe doo with the Eagle Mike doo but I didn't want to do it this time around...time contraints, I was getting the KLR ready for an RTE this weekend (which I subsequently missed=:-( Anyways, > > > It would be prudent to pull the rotor to look for the missing washer, and do the doo at the same time. I'd phoned my local dealer to see if they had one of these washers in stock, they don't so I'm taking it down to do the doo while I wait for the part, in the event the washer never made it on when the motor was originally assembled > > > I came up with that theory when I took a good long hard look at the hole in the inner cover where the lower starter gear butts agasinst it, where the washer is missing. My conclusion?, the surface where the washer would sit looks traumatized, unlike the other 3 alloy surfaces where there was a washer (part# 92022) > > > here's a pic of the inner case hole, where I didn't find the washer > > > http://tinyurl.com/yzq55cl > > > I'm wondering...has anyone else on this list come across one of these washers missing when you did your doo mod? > > > Just curious... > > > > > > Jake > Reddick Fla. > Many people claim coffee inspires them, but, as everybody knows, coffee only makes boring people even more boring. > -- Honore de Balzac >

[guymanbro]

> On Oct 24, 2009, at 6:11 PM, glennlpf wrote: > > > I have an '09 (and an FJR1300) and I noticed that if you stall the KLR that you HAVE to put it in neutral to re-start it. Not so with my FJR. Upon initial startup, this isn't a big deal, but if you stall it at a light (which I do more seldom now than when I first got the bike), you have to hunt around for neutral before it will restart. On my FJR, I just kick it over no matter what gear I'm in (as long as the clutch is pulled in, of course). . > >

Sounds exactly like a faulty clutch safety switch. Bypassing that switch (albeit on a pre '08 KLR) fixed the same symptoms for me. da Vermonster