[dsn_klr650] klr 650 : 685 kit

[spike55_bmw]

I just posted some before and after pictures of the swing arm. What a slimy dirty rotten mess getting 3.5 yrs worth of crud off of the chain guard and slider areas. I used a large kitty litter bucket with 2 gals of oil partswasher fluid. Plan to mix that in with my waste oil for a friend's garage heater. Removing the pivot bolt was a bit tense, as you can see it was rusty in the middle and held fast to the sleeve through the pivot lever. I'm not sure there is a long term cure for the rust, since greasing it will allow the bearing's inner sleeve to rotate around the bolt rather than having the surrounding needle bearings rotate around the sleeve, as designed. I now have to re-read the 'watt-man' files on Zerk installation. More later. BTW - I now have a new base and head gasket for the cylinder (ball-honed in new cross-hatching but otherwise stock). All stock ring gaps were well within spec after 22.6K, so I'll keep it stock. Don R100, A6F

[Michael Martin]

Don, I greased the bolt on my bike, reasoning that the needle bearings would not have enough drag to cause the inner sleeve to rotate. Mike Martin, Louisville, KY [b]From:[/b] spike55_bmw [b][/b] Removing the pivot bolt was a bit tense, as you can see it was rusty in the middle and held fast to the sleeve through the pivot lever. I'm not sure there is a long term cure for the rust, since greasing it will allow the bearing's inner sleeve to rotate around the bolt rather than having the surrounding needle bearings rotate around the sleeve, as designed.

[Jeff Saline]

#ygrps-yiv-479091033 .ygrps-yiv-479091033ygrp-photo-title { CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;WIDTH:75px;HEIGHT:15px;TEXT-ALIGN:center;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033ygrp-photo { BORDER-RIGHT:black 1px solid;BACKGROUND-POSITION:center 50%;BORDER-TOP:black 1px solid;BORDER-LEFT:black 1px solid;WIDTH:62px;BORDER-BOTTOM:black 1px solid;BACKGROUND-REPEAT:no-repeat;HEIGHT:62px;BACKGROUND-COLOR:white;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033attach-table DIV.ygrps-yiv-479091033attach-row { CLEAR:both;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033attach-table DIV.ygrps-yiv-479091033attach-row DIV { FLOAT:left;} #ygrps-yiv-479091033 P { CLEAR:both;PADDING-RIGHT:0px;PADDING-LEFT:0px;PADDING-BOTTOM:3px;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033ygrp-file { WIDTH:30px;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033attach-table DIV.ygrps-yiv-479091033attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033attach-table DIV.ygrps-yiv-479091033attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-479091033 DIV.ygrps-yiv-479091033ygrp-file-title { FONT-WEIGHT:bold;} #ygrps-yiv-479091033 DIV { MARGIN:0px;} Got hosed by Yahoo and Juno again.  Sorry. <><><><><><> <><><><><><>   TK,   Thanks for the detailed reply.  You sure did more investigation than I did.   I'm curious if you still have the data and it's easily available what the changes in sizes were for both the cylinder and piston at the different temperatures.   I'm kind of interested in the clearances you used at 200 degrees and how they relate to clearances at room temp.   Thanks and best,   Jeff   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   ----- Forwarded Message ----- [b]From:[/b] Thomas Komjathy [b]To:[/b] Jeff Saline , DSN_klr650@yahoogroups.com [b]Date:[/b] Mon, 14 Dec 2009 07:24:56 -0800 (PST) [b]Subject:[/b] Re: Re: [DSN_KLR650] KLR 650 : 685 kit [b]Message-ID:[/b] [b]References:[/b]   Hi Jeff  You are correct, the bore should be kept cool and at a constant temperature when bored. We were testing some thoughts we had about boring and because the KLR has such a big bore, we decided to test our theory on it. We measured the bore at 70 degrees, no torque plate, then installed and torqued the cylinder and found some distortion. Then we heated the cylinder to 200 degrees in an oil bath, measured the bore and found different readings as well. The final step was; we heated the cylinder, applied the torque plate and found a third set of readings/measurements. So we, heated to 200 degrees, applied the torque plate, bored and honed; the oil bath kept the cylinder at a constant 200 degrees and carried the interface heat between the bit and sleeve away quickly. It is the best sealing cylinder we have bored and honed so far. We also heated the piston and measured it, then matched the clearances between the bore and piston. I know this sounds a bit laborious for a boring job, but it was really more about testing thoughts on boring, I'm weird like that. TK [b]From:[/b] Jeff Saline [b]To:[/b] DSN_klr650@yahoogroups.com [b]Sent:[/b] Mon, December 14, 2009 12:48:23 AM [b]Subject:[/b] Fw: Re: [DSN_KLR650] KLR 650 : 685 kit   List,   Sorry about the blank e-mail.  Yahoo sometimes won't show messages from Juno accounts but sends the original message.  Hopefully this comes through.  Below is what I sent to Thomas.   Best,   Jeff <><><><><><> <><><><><><> Thomas,   Last winter I did a bit of research on the need for torque plates for KLR cylinder boring.  The advice I got from the "experts" was torque plates were not needed for the KLR650 cylinders.  What is needed is making sure the cylinder doesn't get "hot" during the boring or honing process.   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     ----- Forwarded Message ----- [b]From:[/b] Thomas Komjathy [b]To:[/b] Luc Legrain , DSN_KLR650@yahoogroups.com [b]Date:[/b] Wed, 9 Dec 2009 09:07:16 -0800 (PST) [b]Subject:[/b] Re: [DSN_KLR650] KLR 650 : 685 kit [b]Message-ID:[/b] [b]References:[/b]   Depends on how many miles you have on it. do try to find a shop that can bore and hone with a torque plate for the best piston to cylinder fitment. [b]From:[/b] Luc Legrain yahoo.com> [b]To:[/b] DSN_KLR650@yahoogro ups.com [b]Sent:[/b] Wed, December 9, 2009 11:45:08 AM [b]Subject:[/b] [DSN_KLR650] KLR 650 : 685 kit   Well ... Winter project " 685 kit ". Besides the basics what do you all suggest should be done while the motor is open . Gimme the Must Be done and the could be done . Thanks . ____________________________________________________________ Diet Help Cheap Diet Help Tips. Click here.

[sh8knj8kster]

--- In DSN_KLR650@yahoogroups.com, "spike55_bmw" wrote:

> > I just posted some before and after pictures of the swing arm.

~~~~where? Jake Reddick Fla.