[bulk] [dsn_klr650] o a s

[hansenj32]

In the summer I usually remove my hand guards, replace them in the fall & remove my choke lever when doing so to access the lower left-hand nut. Today as I was replacing the guards, the threads in the switch housing for choke lever screw stripped. I was hopping there are extra threads beyound the damaged area so I could use a longer screw. But using a bent piece of safety wire tells me there may be one if that. My next stop was to check pricing for a new housing at BikeBandit.com & was none too thrilled w/ the price. Then I figured a Heli-Coil should do the trick, but in checking around - nobody carries one smaller than 6 mm & I need 5. Any suggestions as to who might have thread inserts or Heli-Coils in 5 mm or other ways to repair the damage? Jake

[greg coyle]

yea thanks. don't remind me...i still drool over that duc. only $800 brand new in 1962...

On 9/17/2012 6:36 PM, Ron Criswell wrote: > I traded my piece of crap 250 BSA for a 250 Ducati single. I loved the > engine on the Duc....but, don't leave the gas on....or you will have a > crankcase full of gas. The electric system had issues. I sold that bike > to my brother for $75. He thought he got screwed. That bike today would > bring at least 5 grand....at least. > > Criswell > > Sent from my iPad > > On Sep 17, 2012, at 6:34 PM, greg coyle > wrote: > > > Criswell., > > thanks for sending me down a nostalgia trip > > when push came to shove my dad 'forced' to get a motorcycle instead of > > the cushman which all of my friends had. thank goodness. i was 13 at the > > time and we went and looked seriously at the new 250 ducati. oh if i > > could roll back time on that decision... after i got my 100cc parilla my > > neighbor, not to be outdone, went down and got the harley scat... oh > > fond memories...thanks... > > greg > > > > On 9/16/2012 4:43 AM, Ron Criswell wrote: > > > Yeah Andy, bikes today are a little more reliable than yesterday's > > > bikes. My buddy had a 76 Sportster that had issues. It had an oil leak > > > so bad, the rear tire was wet with oil (shiny wet). I told him he > needed > > > to fix that because hr was going to fall on his ass leaning into a > turn. > > > His response was "oh we don't lean much" (heh). He had a bad gas leak > > > out of the engine spraying gas all over the engine. Reminded mr of the > > > song Light My Fire. He never fixed that. He was too busy adding > fenders, > > > ape hangers and stuff. > > > > > > My worst Two wheeler was my Cushman Highlander. I wanted a Harley > Hummer > > > but Dad in his infinite wisdom said motorcycles were dangerous....so > > > bought me the used Highlander for $75. It had a headlight with the > power > > > of a cigarette lighter. It had one lousy and questionable rear brake. > > > The ....ahh....suspension was two springs in front. Very high tech and > > > fancy (heh). It would go just fast enough to kill you....but would take > > > a block or two to get there. > > > > > > It never lived again after our cousin showed us how to take the engine > > > apart to over haul it. This was a good thing. A much better brand new > > > Vespa followed it. Night and day difference in technology. > But....sadly, > > > my crashing and wrenching completely distorted it in a year and a half. > > > A friend had a Lambretta.....better still. > > > > > > Another friend bought a Japanese scooter (the first thing I saw from > > > Japan). It looked kinda like that old Harley scooter (Topper I think it > > > was called). This Japanese scooter had electric, orange turn signals. > > > Very new and girley, girley....but safe. > > > > > > Criswell > > > > > > Sent from my iPad > > > > > > On Sep 15, 2012, at 11:18 PM, "achesley43@... > > > > " > > > > wrote: > > > > > > > > > > > > > > > --- In DSN_KLR650@yahoogroups.com > > > > , Ron Criswell > > > wrote: > > > > > > > > > > I had a BSA 250 with the same alloy tank the Victor had. It was pre > > > Victor. It would literally unscrew itself riding along. I sold the BSA > > > when the spark plug blew out and hit me in the leg. > > > > > > > > > > Criswell > > > > > > > > That got a laugh out of me Ron. LOL! My '69 Norton Commando had a > > > habit of unscrewing the mains and letting them drop to the bottom > of the > > > float bowels. My '72 Honda 750K2 didn't like me not tighten up the rear > > > after a drunken : just had to adjust the chain one night : so it broke > > > the chain and wiped out the engine case in front of the sprocket. I > > > showed it whom was boss with some Alu Plate and plastic metal; every > > > 1000 miles had to add plastic though. Oh, my '59 Triumph 500 didn't > > > like spinning the rear tire in grass and hitting pavement with it > > > spinning. Broke the Transmission 2 times like that. And, sadly, I was > > > prewarned by the Triumph Dealer about the weakness in the 500 trans. Oh > > > Well, that taught me how to rebuild that transmisson in 1960 at 17 > years > > > old. LOL! Out of the 5 Harley's I had, the last one, a 1975 ( think ) > > > Superglide was the most dependable cept for breaking the coil > bracket on > > > a run. The BMW's ( '95 R11GS; '97 R11R and the '02 R1150Gs ) were the > > > easiest to maintain. No problems in the 125,000 miles I put on them. I > > > think I was on the '02 when I met you guys in Southern Colorado coming > > > back from Washington. > > > > > > > > > > > > > > [Non-text portions of this message have been removed] > > > > > > > > > > [Non-text portions of this message have been removed] > >

[RobertWichert]

I changed to the better switch housing with push-to-reset on my '07 and added the necessary choke lever bracket. They aren't expensive, but if you absolutely must have the crappy stock unit, I might sell it to you for cheap. What's it worth? OK, cheapest way is probably Devcon or some sort of liquid aluminum. You may have to break it to get it out, but I suspect that it will stay in there just fine. You'll also need to strap it in place against the spring pressure. You could try filling it up with Devcon or liquid aluminum and drilling it out and tapping it. That "might" work. Oh, hell, just buy mine. Or if it's '08 or later, sorry... Can't help. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 9/18/2012 3:47 PM, hansenj32 wrote: > > > In the summer I usually remove my hand guards, replace them in the fall > & remove my choke lever when doing so to access the lower left-hand nut. > Today as I was replacing the guards, the threads in the switch housing > for choke lever screw stripped. I was hopping there are extra threads > beyound the damaged area so I could use a longer screw. But using a bent > piece of safety wire tells me there may be one if that. My next stop was > to check pricing for a new housing at BikeBandit.com & was none too > thrilled w/ the price. Then I figured a Heli-Coil should do the trick, > but in checking around - nobody carries one smaller than 6 mm & I need > 5. Any suggestions as to who might have thread inserts or Heli-Coils in > 5 mm or other ways to repair the damage? > > Jake > > [Non-text portions of this message have been removed]

[Jeff Saline]

On Tue, 18 Sep 2012 22:47:23 -0000 "hansenj32" writes:

> > In the summer I usually remove my hand guards, replace them in the > fall > & remove my choke lever when doing so to access the lower left-hand > nut. > Today as I was replacing the guards, the threads in the switch > housing > for choke lever screw stripped. I was hopping there are extra > threads > beyound the damaged area so I could use a longer screw. But using a > bent > piece of safety wire tells me there may be one if that. My next stop > was > to check pricing for a new housing at BikeBandit.com & was none too > thrilled w/ the price. Then I figured a Heli-Coil should do the > trick, > but in checking around - nobody carries one smaller than 6 mm & I > need > 5. Any suggestions as to who might have thread inserts or Heli-Coils > in > 5 mm or other ways to repair the damage? > > Jake

<><><><> <><><><> Jake, Two methods I can think of to address this issue are to weld the hole and then drill and thread to the proper size. The other method is replace the choke mount with a clutch perch cap that is a combination mirror mount and choke mount. I think a few places sell them and maybe Fred can share if he's one of the sellers. I suppose they would cost less than $25. I made two in 2004 as a machining exercise. The one on my bike is probably worth about $200 based on how complicated it was to make. : ) 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 . . ____________________________________________________________ Woman is 53 But Looks 25 Mom reveals 1 simple wrinkle trick that has angered doctors... http://thirdpartyoffers.juno.com/TGL3141/50591e00347691dff2226st01vuc

[Fred Hink]

Yes, I sell the clutch perch/choke mount with mirror mount. ($17) One suggestion I have is maybe you could find a self-threading screw that would fit your stripped out threads. Since this isn t a high stress application, it wouldn t take much to hold your choke lever on. You might also try some QuikSteel in the stripped out hole and then drill and tap to fit your bolt. Fred www.arrowheadmotorsports.com From: Jeff Saline Sent: Tuesday, September 18, 2012 7:19 PM To: hansenj32@... Cc: DSN_KLR650@yahoogroups.com Subject: Re: [DSN_KLR650] Stripped Choke Lever Screw Thread On Tue, 18 Sep 2012 22:47:23 -0000 "hansenj32" writes:

> > In the summer I usually remove my hand guards, replace them in the > fall > & remove my choke lever when doing so to access the lower left-hand > nut. > Today as I was replacing the guards, the threads in the switch > housing > for choke lever screw stripped. I was hopping there are extra > threads > beyound the damaged area so I could use a longer screw. But using a > bent > piece of safety wire tells me there may be one if that. My next stop > was > to check pricing for a new housing at BikeBandit.com & was none too > thrilled w/ the price. Then I figured a Heli-Coil should do the > trick, > but in checking around - nobody carries one smaller than 6 mm & I > need > 5. Any suggestions as to who might have thread inserts or Heli-Coils > in > 5 mm or other ways to repair the damage? > > Jake

<><><><> <><><><> Jake, Two methods I can think of to address this issue are to weld the hole and then drill and thread to the proper size. The other method is replace the choke mount with a clutch perch cap that is a combination mirror mount and choke mount. I think a few places sell them and maybe Fred can share if he's one of the sellers. I suppose they would cost less than $25. I made two in 2004 as a machining exercise. The one on my bike is probably worth about $200 based on how complicated it was to make. : ) 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 . . __________________________________________________________ Woman is 53 But Looks 25 Mom reveals 1 simple wrinkle trick that has angered doctors... http://thirdpartyoffers.juno.com/TGL3141/50591e00347691dff2226st01vuc [Non-text portions of this message have been removed]

[RobertWichert]

NOT STEEL! Devcon makes aluminum, brass, steel, a lot of different formulations. The key is thermal expansion. Match it and it lasts. Don't match it and it's history. I have a boat application (front nose cone on an outdrive) that has lasted twenty four years, hit numerous rocks, stumps, sand and gravel, and is still in perfect shape (except for a few gouges)... Devcon, baby! It's the real deal! Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 9/18/2012 6:29 PM, Fred Hink wrote: > > Yes, I sell the clutch perch/choke mount with mirror mount. ($17) > > One suggestion I have is maybe you could find a self-threading screw > that would fit your stripped out threads. Since this isn t a high > stress application, it wouldn t take much to hold your choke lever on. > You might also try some QuikSteel in the stripped out hole and then > drill and tap to fit your bolt. > > Fred > www.arrowheadmotorsports.com > > From: Jeff Saline > Sent: Tuesday, September 18, 2012 7:19 PM > To: hansenj32@... > Cc: DSN_KLR650@yahoogroups.com > Subject: Re: [DSN_KLR650] Stripped Choke Lever Screw Thread > > On Tue, 18 Sep 2012 22:47:23 -0000 "hansenj32" > > writes: > > > > In the summer I usually remove my hand guards, replace them in the > > fall > > & remove my choke lever when doing so to access the lower left-hand > > nut. > > Today as I was replacing the guards, the threads in the switch > > housing > > for choke lever screw stripped. I was hopping there are extra > > threads > > beyound the damaged area so I could use a longer screw. But using a > > bent > > piece of safety wire tells me there may be one if that. My next stop > > was > > to check pricing for a new housing at BikeBandit.com & was none too > > thrilled w/ the price. Then I figured a Heli-Coil should do the > > trick, > > but in checking around - nobody carries one smaller than 6 mm & I > > need > > 5. Any suggestions as to who might have thread inserts or Heli-Coils > > in > > 5 mm or other ways to repair the damage? > > > > Jake > <><><><> > <><><><> > > Jake, > > Two methods I can think of to address this issue are to weld the hole and > then drill and thread to the proper size. > > The other method is replace the choke mount with a clutch perch cap that > is a combination mirror mount and choke mount. I think a few places sell > them and maybe Fred can share if he's one of the sellers. I suppose they > would cost less than $25. I made two in 2004 as a machining exercise. > The one on my bike is probably worth about $200 based on how complicated > it was to make. : ) > > 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 > > . > . > __________________________________________________________ > Woman is 53 But Looks 25 > Mom reveals 1 simple wrinkle trick that has angered doctors... > http://thirdpartyoffers.juno.com/TGL3141/50591e00347691dff2226st01vuc > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

[Jud]

--- In DSN_KLR650@yahoogroups.com, RobertWichert wrote:

> > NOT STEEL! > Devcon, baby! It's the real deal! > >

You can say that again. I once shared shop space with a very talented guy who built a BSA twingle, that is, a 650 twin set up to run as a single, with both cylinders firing at once. He built it with belt drive. Since he could not just go out and buy belt drive pulleys for an old BSA, he molded them up out of Devcon. It worked, and continued to work for a couple of years until he got tired of the bike and it faded from view.

[hansenj32]

Thanks to all for your input. I just got off the phone with our local fastener store and they carry a Heli-Coil kit for the 5mm thread which includes a dozen inserts. That was great news, but at $35 for the kit, I need to weigh that versus the Eagle choke/mirror relocation kit at half the cost. I'm very happy w/ the stock choke location, not too excited about having an extra mirror mount & so, may spring for the Heli-Coil instead. Again, thanks for all the responses.

--- In DSN_KLR650@yahoogroups.com, "hansenj32" wrote: > > > In the summer I usually remove my hand guards, replace them in the fall > & remove my choke lever when doing so to access the lower left-hand nut. > Today as I was replacing the guards, the threads in the switch housing > for choke lever screw stripped. I was hopping there are extra threads > beyound the damaged area so I could use a longer screw. But using a bent > piece of safety wire tells me there may be one if that. My next stop was > to check pricing for a new housing at BikeBandit.com & was none too > thrilled w/ the price. Then I figured a Heli-Coil should do the trick, > but in checking around - nobody carries one smaller than 6 mm & I need > 5. Any suggestions as to who might have thread inserts or Heli-Coils in > 5 mm or other ways to repair the damage? > > Jake >