fixed it! choke lever problems - 2007 klr 650

[Jeffrey]

I had one of the older over-sized front rotor kits on my 2004. When I got it, the relocation bracket would rub on the rotor mounting allen bolts. I just ground dn the relocation bracket. It took a dozen attempts because I didn't want to grind too much away. Fast forward 6 years and after living near the beach and using locktite, I finally stripped the aluminum relocation bracket threads even though I used a torque wrench. Electrolysis(disimilar metals),corrosion and loctite stuck in the threads... So, even though it wasn't their fault that the threads stripped, I complained about the bracket being engineered wrong and what a hassle it was to grind to fit which was their fault. Once I documented with closeups the problem, EBC is sending me the whole newer mo betta front front rotor kit and I am sending them the old stuff back so they can analyze/improve/troubleshoot. A few people had the same relocation bracket issue and some had brake pad compatibility issues with the larger front rotor. The pad issue was mostly from using off brand non-EBC brake pads. I NOW PUT EBC BRAKES IN THE SAME CLASS AS EAGLE-MIKE MFG AND ENGINEERING! SUPPORT EBC BRAKES AND EAGLE-MIKE! Jeffrey #3

[Jeff Khoury]

My experience with EBC is different than yours. I went to my local dealer to get a set of front brake pads for my '09. They didn't have any OEM pads so they sold me a set of EBCs. After installing them, the brake lever felt mushy and required much more pressure to stop. I double checked to ensure they were installed right and chalked it up to needing to be worn in a bit. Problem is, they never "wore in". After a thousand miles or so and a couple of scary stops, I ordered a set of OEM pads online and installed them. From stop #1 by lever firmness was back and required much less pressure. In fact, I really had to be careful because I was so used to crushing my brake lever that I nearly locked the front wheel a couple of times. Now, I know that they make different compounds for the KLR, but based on that experience I don't think I'll be giving them another try. -Jeff Khoury From: "Jeffrey" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Friday, May 13, 2011 5:09:52 PM Subject: [DSN_KLR650] EBC makes good! I had one of the older over-sized front rotor kits on my 2004. When I got it, the relocation bracket would rub on the rotor mounting allen bolts. I just ground dn the relocation bracket. It took a dozen attempts because I didn't want to grind too much away. Fast forward 6 years and after living near the beach and using locktite, I finally stripped the aluminum relocation bracket threads even though I used a torque wrench. Electrolysis(disimilar metals),corrosion and loctite stuck in the threads... So, even though it wasn't their fault that the threads stripped, I complained about the bracket being engineered wrong and what a hassle it was to grind to fit which was their fault. Once I documented with closeups the problem, EBC is sending me the whole newer mo betta front front rotor kit and I am sending them the old stuff back so they can analyze/improve/troubleshoot. A few people had the same relocation bracket issue and some had brake pad compatibility issues with the larger front rotor. The pad issue was mostly from using off brand non-EBC brake pads. I NOW PUT EBC BRAKES IN THE SAME CLASS AS EAGLE-MIKE MFG AND ENGINEERING! SUPPORT EBC BRAKES AND EAGLE-MIKE! Jeffrey #3 [Non-text portions of this message have been removed]

[k650@verizon.net]

EBC makes at least two or three different compound pads for the KLR. The OEM pads are sintered so unless you had EBC sintered pads you would be comparing apples to oranges. Walt -----Original Message----- From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of Jeff Khoury Sent: Saturday, May 14, 2011 03:01 To: Jeffrey Cc: DSN KLR650 Subject: Re: [DSN_KLR650] EBC makes good! My experience with EBC is different than yours. I went to my local dealer to get a set of front brake pads for my '09. They didn't have any OEM pads so they sold me a set of EBCs. After installing them, the brake lever felt mushy and required much more pressure to stop. I double checked to ensure they were installed right and chalked it up to needing to be worn in a bit. Problem is, they never "wore in". After a thousand miles or so and a couple of scary stops, I ordered a set of OEM pads online and installed them. From stop #1 by lever firmness was back and required much less pressure. In fact, I really had to be careful because I was so used to crushing my brake lever that I nearly locked the front wheel a couple of times. Now, I know that they make different compounds for the KLR, but based on that experience I don't think I'll be giving them another try. -Jeff Khoury From: "Jeffrey" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Friday, May 13, 2011 5:09:52 PM Subject: [DSN_KLR650] EBC makes good! I had one of the older over-sized front rotor kits on my 2004. When I got it, the relocation bracket would rub on the rotor mounting allen bolts. I just ground dn the relocation bracket. It took a dozen attempts because I didn't want to grind too much away. Fast forward 6 years and after living near the beach and using locktite, I finally stripped the aluminum relocation bracket threads even though I used a torque wrench. Electrolysis(disimilar metals),corrosion and loctite stuck in the threads... So, even though it wasn't their fault that the threads stripped, I complained about the bracket being engineered wrong and what a hassle it was to grind to fit which was their fault. Once I documented with closeups the problem, EBC is sending me the whole newer mo betta front front rotor kit and I am sending them the old stuff back so they can analyze/improve/troubleshoot. A few people had the same relocation bracket issue and some had brake pad compatibility issues with the larger front rotor. The pad issue was mostly from using off brand non-EBC brake pads. I NOW PUT EBC BRAKES IN THE SAME CLASS AS EAGLE-MIKE MFG AND ENGINEERING! SUPPORT EBC BRAKES AND EAGLE-MIKE! Jeffrey #3 [Non-text portions of this message have been removed] ------------------------------------ List Sponsors - Dual Sport News: http://www.dualsportnews.com Arrowhead Motorsports: http://www.arrowheadmotorsports.com List FAQ courtesy of Chris Krok: http://www.bigcee.com/klr650faq.html Member Map: http://groups.yahoo.com/group/DSN_KLR650/app/peoplemap/view/map Group Apps: http://groups.yahoo.com/group/DSN_KLR650/grouplets/subscriptionsYahoo! Groups Links

[Jeffrey]

I know people who had the same problem. But, as you said EBC makes several different compounds. Some of those will be firmer or softer than OEM. OEM is a ripoff and isn't made by Kawasaki, Suzuki, BMW, Mercedes, Toyota etc. OEM is made by a parts supplier to Mfr. specs. The soft pads would have been swapped by EBC corp. for a more appropriate pad. When I initially got my OVERSIZED rotor kit, it came with some super hard motard EBC pad. Those pads stopped really well but made noise because they were so hard(I think they had way to much metal in them for my use; no stoppies for me). I should have swapped these. The thing about contacting EBC is there website forces you to use Outlook Express to contact them--which I don't use. It took some searching but I finally found their phone number which was in Washington State. I am sure Fred could help us out with EBC because he sells their products; esp. if you buy from him. I have tried EBC automotive pads and they are great also but a bit pricey. Jeffrey #3

[Jeff Khoury]

I'm sure their sintered pads are better. The ones I had were downright dangerous. If I were EBC, I would not even offer them. -Jeff Khoury From: "Jeffrey" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Saturday, May 14, 2011 7:54:32 AM Subject: [DSN_KLR650] Re: EBC makes good! I know people who had the same problem. But, as you said EBC makes several different compounds. Some of those will be firmer or softer than OEM. OEM is a ripoff and isn't made by Kawasaki, Suzuki, BMW, Mercedes, Toyota etc. OEM is made by a parts supplier to Mfr. specs. The soft pads would have been swapped by EBC corp. for a more appropriate pad. When I initially got my OVERSIZED rotor kit, it came with some super hard motard EBC pad. Those pads stopped really well but made noise because they were so hard(I think they had way to much metal in them for my use; no stoppies for me). I should have swapped these. The thing about contacting EBC is there website forces you to use Outlook Express to contact them--which I don't use. It took some searching but I finally found their phone number which was in Washington State. I am sure Fred could help us out with EBC because he sells their products; esp. if you buy from him. I have tried EBC automotive pads and they are great also but a bit pricey. Jeffrey #3 [Non-text portions of this message have been removed]

[skypilot110]

It isnt forcing you to use a program. It is opening an email to send to them. You need to set your default email program in Windows to the program you want to send emails from

> > > From: "Jeffrey" > To: "DSN KLR650" DSN_KLR650@yahoogroups.com> > Sent: Saturday, May 14, 2011 7:54:32 AM > Subject: [DSN_KLR650] Re: EBC makes good! > > > The thing about contacting EBC is there website forces you to use Outlook Express to contact them--which I don't use. It took some searching but I finally found their phone number which was in Washington State. >

[RobertWichert]

Two changes appear to have fixed this: 1) Removed one of the wave washers. I figured one was enough and two might be too many. I could have picked up the extra as part of the new lever from the parts bag, while still having the old one on there from before. Having two could have put too much pressure on the rotating portion, causing high friction between the washers, the rotating lever portion, and the screw. 2) Made absolutely sure that the two washers -- one flat washer and one little round guy, like an o-ring (I hadn't seen this before today and it's not on the parts fiche - http://www.ronayers.com/Fiche/TypeID/26/Type/Handlebar/MakeID/3/Make/Kawasaki/YearID/39/Year/1998/ModelID/4505/Model/KLR650/GroupID/140061/Group/Handlebar ) were properly seated in the depression in the lever rotating portion (for the little round guy) and between the rotating portion of the lever and the screw. I heard and felt a "pop" when this went together properly. It's all good now (I hope). Robert P. Wichert P.Eng LEED AP +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 5/18/2011 6:02 AM, mechanizeinc wrote: > > Plus eleven on the use of LocTite... > > job done. > > I relocated my mirrors to avoid breaking the left switch housing. The > right mirror was relocated off the bike and then used on the left > after I broke the left. I used to remove the mirrors and my tool bag > every time I'd drop into the trails. > > Bought a KTM folding mirror. Looks like the OEM round mirror or 1st > gen bikes. A bit longer so you can see more than your shoulder. > Slightly reduced vibes and it folds down to the bar without tools. > > Now all I stash at the trail head is the tool bag and maybe a layer of > cloths. > > Mech > > --- In DSN_KLR650@yahoogroups.com > , RobertWichert wrote: > > > > I replaced my choke lever and messed it up. My old one broke in one of > > my numerous falls, so I replaced it with a new Kawi part. (Has anybody > > ever taken their mirrors off before riding off-road to avoid knocking > > them loose like I do every damned time that I fall?) > > > > Back to my choke lever - It now backs out the screw that holds it > > together, a little bit every time I use it. After a few uses, the screw > > is loose and I have to tighten it again. If I over tighten it, it's > > hard to move the lever the first time I use it, but once I cycle it a > > few times the screw backs out and it gets easier. Eventually the screw > > is too loose and needs to be over tightened again. I know that I > > assembled it wrong, but I don't know what I did wrong. It has two wave > > washers, which is what I suspect I screwed up. The stacking order now > > is like this: > > Starting at the handlebar > > Support > > Stationary portion > > Wave washer 1 > > Wave washer 2 > > Rotating portion > > Small flat washer > > Allen screw > > > > The screw may be too long or the wrong one, or it may be missing some > > sort of internal tubular stop piece (grasping for solutions here) > that I > > have lost. > > > > Any ideas out there? Fred? > > > > > > -- > > > > > > > > Robert P. Wichert P.Eng LEED AP > > +1 916 966 9060 > > FAX +1 916 966 9068 > > > > > > > > > > > > > > > > > > > > > > > > =============================================== > > > > [Non-text portions of this message have been removed]