emergency parts?

[grbhfng]

For what it's worth, my own problems with brake bleeding. 2008 KLR. I picked up something in my rear caliper [rock ?] that scared the piss out of me with the noise, and even worse, the reduction in braking power. Since I had a set of new Galfer pads, I just decided to do a pad change, since whatever it was, had scored the rotor. Rears went in, no problem. Bled OK. Fronts in, and I had the same condition you described. No amount of bleeding would get me anything. Now, I'm not an expert mechanic, but my younger brother is ASME certified, and he said, "Take it apart, you did something wrong." When I took the caliper off, I noticed the piston side pad was cocked to one side, caused by the backing plate on the pad hanging up in the caliper, so only one piston was extending. Removed pad and compared it with the original ones, and the backing plate was a small amount wider than the original. From my years as a QC Inspector, I figure that the difference was enough to cause Tolerance Stack, making the pad too wide for the caliper. Put things back together with original front pads, everything worked fine. The backing plates are made using a punch press operation, which leaves a shear burr on the edges, which is what appears to be causing the problem.

--- On Thu, 7/31/08, clutz003 wrote: From: clutz003 Subject: [DSN_KLR650] Issues with front brake bleeding To: DSN_klr650@yahoogroups.com Date: Thursday, July 31, 2008, 7:59 PM I put on a new Galfer front brake line yesterday. I primed the line with brake fluid before tightening the bottom banjo bolt then filled up the master cylinder with fluid and began the bleeding process. I can't get any resistance on the brake lever. There appears to be fluid throughout the system, as when I take out the bleeder valve fluid runs out of the hole. When I open the valve and depress the lever only a very small amount of fluid comes out. There is not nearly enough pressure to even think about using the speed bleeder. I let it set overnight with the lever fully compressed (recommended per review of the archives) but still the same story today. Any suggestions? Thanks, Craig A18 San Jose CA [Non-text portions of this message have been removed]

[nakedwaterskier]

Motorcycle brake bleeding has always been simple for me. You don't even need anyone else to step on the pedal like in a car or truck.(Or operate the lever cuz u can reach it on most bikes.) For tough bleeds, you just use a tight fitting clear plastic hose into a bottle with a few inches of brake fluid in it. And don't loosen the valve too much and make sure u keep topping off the master cylinder. It aint Nucular physics! Nucular is an ad hoc spelling of an incorrect pronunciation of the word nuclear, representing the IPA: /ˈnju kjələr/ (NEW-cue-lurr) pronunciation of that word instead of the correct /ˈnju kli ɚ/ (NEWK-lee-urr). This pronunciation is disapproved, although some dictionaries recognize it because of its increasing usage.[1] Rear brakes can sometimes have an air bubble in them if the hose goes up then dn to the calipers on/near the swingarm. And you might need to detach the hose guide to push dn the hose. But, I have never had to do that. But Geoffrey Nunberg, a linguist at Stanford University, believes Bush - a Yale graduate from a wealthy family - knows the correct way but chooses the "Bubba pronunciation" to sound more folksy. Nunberg calls it "faux Bubba." Lots of people go "nuculer." Presidents Eisenhower, Ford, Carter and Clinton all had difficulty saying the word. Carter's mispronunciation seemed at least partly due to his Southern accent, but it was unusual because he studied nuclear physics in graduate school. Ford had so much trouble that his speechwriters avoided using the word, often substituting "atomic," according to Allan Metcalf, an English professor at MacMurray College in Jacksonville, Ill., and author of several books on language.

[Bogdan Swider]

On 8/3/08 8:03 PM, "David Bell" wrote:

> > > > I am going to Mexico in October to do some ds riding south of Monterrey. I am > going over the 2002 KLR that I bought. I have installed crash bars, skid > plate, caribou bags, and plan on an improved low beam and brake pads and > Rotors. I will put in the doohickey in a couple of weeks. > > I am buying spare clutch cable, throttle cables. > > I was considering spare chain and chain breaker tools. >

Dave, I ve taken a number of trips from Colorado through Mexico to Central America and a few into Baja and mainland Mexico. Some thoughts: Monterrey is just over the border. It s also a modern city in the most developed part of Mexico; very different from Mexico further in. I d take the same stuff you d take while on a trip in the US or Canada. If the chain and sprockets are in good shape, I wouldn t bother with chain tools; I also don t believe you need to install a new chain for such a short trip. Lube it every night of course plenty of WD-40 all over Mexico. Don t ride at night. Mexican vehicles leak more fluids than ours. Therefore the roads can be very slick especially after periods of little rain common in the north. Bogdan [Non-text portions of this message have been removed]