wheel swap klr600 vs. klr650

[madmotorcyclist2001]

Jim, your description of the problem of the falling washer is well done. I re-read Mark's instructions, and though he does mention the possiblity of the washer falling, he kind of brushes over it as not too likley unless you are changing your dohickey with the bike on the side stand. It's a highly likely event, even if you are doing the job on a center stand or laying on its side, because the shaft tends to pull out as you remove the inner cover. Joe Grove Jonesboro, AR

[Michael Silverstein]

When I pulled the outer case off one of the starter gear thrust washers fell behind the stator without my knowing. If it weren't for Mark's excellent cautionary notes in his instructions, about keeping track of the thrust washers I would never have known it was missing.

> -----Original Message----- > From: madmotorcyclist2001 [mailto:pgrove@...] > Sent: Saturday, February 26, 2005 6:18 AM > To: DSN_KLR650@yahoogroups.com > Subject: [DSN_KLR650] Re: dohickey gone bad > > > > > Jim, your description of the problem of the falling washer is well > done. I re-read Mark's instructions, and though he does mention the > possiblity of the washer falling, he kind of brushes over it as not > too likley unless you are changing your dohickey with the bike on > the side stand.

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[madmotorcyclist2001]

Yes Michael, You are right about the starter thrust washers and the excellent cautionary notes in Mark's instructions. However, the thrust washer we are talking about here is not one of the starter thrust washers. It is possible for the thrust washer behind the eccentric shaft describe by Jim to fall out and the mechanic not even know it. If the shaft happens to slide part way out while you are removing the inner cover and you just slip it back in without checking for the washer, it could have fallen without your even missing it. You will not see that washer unless you pull the shaft completely out and look for it and make sure it stays on as you put the shaft back in place. Joe Grove

[Krgrife@aol.com]

In a message dated 2/26/2005 2:27:32 P.M. Pacific Standard Time, pgrove@... writes: It is possible for the thrust washer behind the eccentric shaft describe by Jim to fall out and the mechanic not even know it. If the shaft happens to slide part way out while you are removing the inner cover and you just slip it back in without checking for the washer, it could have fallen without your even missing it. You will not see that washer unless you pull the shaft completely out and look for it and make sure it stays on as you put the shaft back in place. Some time ago I printed out all the parts diagrams for my bike from buykawasaki.com and keep them for reference when I do any work. I just look at the diagrams and make sure that the parts I am assembling are all there and in sequence, that eliminates overlooking things like thrust washers that could be missed otherwise. Kurt [Non-text portions of this message have been removed]

[Rodney Copeland]

I hate someone had problems! I learned enough from Mark's instructions, when my shaft came out, I looked, before I pulled it out all the way and the washer stayed stuck on the shaft! Just lucky I guess! Thanks for all you've done for us Mark! You may not be perfect but you're prolly close as we'll find. HHHHAAARRRRR!!!! Cheers, Rod,,,thinkin there are a few that unselfishly help us out there and I for one appreciate the hell out of it!

--- In DSN_KLR650@yahoogroups.com, Krgrife@a... wrote: > > In a message dated 2/26/2005 2:27:32 P.M. Pacific Standard Time, > pgrove@c... writes: > > It is possible for the thrust washer behind the eccentric shaft > describe by Jim to fall out and the mechanic not even know it. If > the shaft happens to slide part way out while you are removing the > inner cover and you just slip it back in without checking for the > washer, it could have fallen without your even missing it. You will > not see that washer unless you pull the shaft completely out and > look for it and make sure it stays on as you put the shaft back in > place. > > > > Some time ago I printed out all the parts diagrams for my bike from > buykawasaki.com and keep them for reference when I do any work. I just look at the > diagrams and make sure that the parts I am assembling are all there and in > sequence, that eliminates overlooking things like thrust washers that could be > missed otherwise. > Kurt > > > [Non-text portions of this message have been removed]

[wannabsmooth1]

--- In DSN_KLR650@yahoogroups.com, "madmotorcyclist2001" wrote:

> > Yes Michael, > > You are right about the starter thrust washers and the excellent > cautionary notes in Mark's instructions. However, the thrust washer > we are talking about here is not one of the starter thrust washers. > It is possible for the thrust washer behind the eccentric shaft > describe by Jim to fall out and the mechanic not even know it. If > the shaft happens to slide part way out while you are removing the > inner cover and you just slip it back in without checking for the > washer, it could have fallen without your even missing it. You will > not see that washer unless you pull the shaft completely out and > look for it and make sure it stays on as you put the shaft back in > place. > > Joe Grove

Looking at the phrasing Paul used, I think he was looking at my set of text instructions. I've now updated them to be VERY detailed on this are, even how to recover if (when) the ^*#@'n washer takes the big slide down into the crankcase. May your washer and your shaft always have the proper relationship..........well, that didn't sound quite right, but you know what I mean. All the best, Mike Eagle Mfg & Eng since 1990 San diego, Ca

[madmotorcyclist2001]

Please do not construe any of my comments to imply I am not grateful for the work Mark did and posted for any of us to use. Without his work, I would have been lost. His instructions were more than adequate, especially the many pictures. As I said earlier, a little more careful reading on my part as I tackled the job, instead of several weeks earlier, would have helped. Thank you Mark. Joe Grove Jonesboro, AR

[John in WV]

From 1st hand experience, NO, the 600 wheel will NOT work on the 650. [w/ stock forks and caliper] John ________________________________ Lurch wrote: Hey all, there is currently a klr600 front wheel listed on ebay, i recently purchased a 95 barbie and the front speedo gear slots on the front hub look to have been beat off with a ball peen hammer. so in short, does anybody know what the difference is between the KLR600 and KLR650 front hub is? i have done part number searches on ron ayers and bike bandit and both parts have similar part numbers that are only one digit off.. My local bike salvage place has a KLR600 wheel in stock and the only difference that i could visably see would be the colors 95 is black 85 is grey (could be sun fade?) please inform.. thank you, Lurch