side panel fasteners

[steventbarnett]

Well, the trip through South America just kind of turned to poop. I'm in Salvador, Brazil with the bike spewing oil through the airbox. Mechanic says the pressure is caused by bad piston and rings (yes, he has taken the engine apart). Problem is in getting new parts to put it back together. Does anything else fit the KLR? Any other suggestions?

[Jeff Saline]

On Tue, 14 Jul 2009 21:15:37 -0000 "steventbarnett" writes:

> Well, the trip through South America just kind of turned to poop. > I'm in Salvador, Brazil with the bike spewing oil through the > airbox. Mechanic says the pressure is caused by bad piston and > rings (yes, he has taken the engine apart). Problem is in getting > new parts to put it back together. Does anything else fit the KLR? > Any other suggestions?

<><><><><><><><><> <><><><><><><><><> Steven, Sorry to hear about the mechanical issues. I'm guessing your cylinder also needs attention since the piston and rings are not serviceable. That would eliminate the possibility of a used piston and rings from another bike. So this might be a time to consider doing a 685 up grade from Schnitz Racing. You'd have to get the 685 piston kit and then get the cylinder bored to size matching your new piston. If you go this route get a new headgasket from them along with all the other gaskets you'll need. The mechanic/machinist will have to resize the headgasket to fit the cylinder. I don't know of any other options unless the cylinder is good and you would be willing to try a stock used piston and rings. But that could be a problem as you'd be hoping for a set that would match your cylinder bore. Can your mechanic or machinist there measure your cylinder bore accurately so you could see if anyone has a used piston that might just fit? I've been told but have no first hand knowledge that the early rings are not available new. No matter what, it seems to me you'll be needing parts brought in to get this situation resolved. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________________________________________________________ Digital Photography - Click Now. http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTDvmS9FhOXk52ccmLDDri9pBZzxugJGmqtRQET13LxbvjAhB73pRm/

[W.V. Doran]

For what it's worth I have used heavey duty velcro to hold the seat in place for years. No problems ever. I made 10mm nut fastners for the side covers but, thats another story. If it's of interest I'll post if you are interested. WVDoran Scottsdale, AZ

--- On Wed, 7/15/09, Jeff Saline wrote: From: Jeff Saline Subject: Re: [DSN_KLR650] side panel fasteners To: transalp1@... Cc: DSN_KLR650@yahoogroups.com Date: Wednesday, July 15, 2009, 12:46 PM On Wed, 15 Jul 2009 14:29:17 -0400 "transalp 1" writes: > I reduced the number of times the side panels will have to be removed > by 10 fold simply by changing to a maint. free battery. > Still, any time you need to remove the seat, you have to undo four > small bolts & take off the side panels. > It got me to thinking: What if the panels had quick disconnect > fasteners? Aircraft ball lock pins came to mind. > But, they are special order and crazy, stupid expensive (along the > lines of $25 each).... AND, I'd have to drill out the threaded holes > - > effectively eliminating going back to OEM fasteners. To make matters > worse, the front two pins would probably protrude from the bolt > holes > and be a nuisance. Then I considered Dzus 1/4 turn fasteners. Neat. > But, still require lots of mods. > > Has anyone come up with a simple, quality replacement for these > bolts that would allow rapid, easy side panel removal? > Electrical wire ties don't count. > > eddie <><><><><><> <><><> <><><><><><> <><><> eddie, I don't have an issue with the stock set up as it works well for me. Two things I've seen that worked well for the riders using modified fastening systems are: - Leave the bolts out of the seat tabs and have a lift off seat. No need to remove the side panels just to get under the seat. If a battery needs to be removed you still have to remove the left side cover. - Drill a hole through the side covers for easy access to the seat bolts. I've seen two versions with just the stock seat bolts and also one I helped a guy with in 2004. He took two longer bolts and put nuts on them in the appropriate position so they would lock the seat in place. I welded the nuts in place and then also welded a flat washer on the end of each bolt so it could act like a wing nut. The washers were just proud of the side covers but that didn't seem to bother the owner. Now, thinking about the question I see I didn't answer it at all as you wanted to know about easy side cover fastening. : ) I recall hearing about but haven't seen someone using heavy duty Velcro to hold them on. Or maybe that was holding the seat on. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads. org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________ _________ _________ _________ _________ _________ _ Click to find the latest solutions to enhance your small business. http://thirdpartyof fers.juno. com/TGL2141/ fc/BLSrjpTI97vpe BJc9Z2SPRmIld8VB t5TkDVBpVyhJqEmr qaln3wyBgDExME/ [Non-text portions of this message have been removed]