Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Kawasaki KLR 600/650 => Topic started by: El Zeffo on February 23, 2007, 07:44:06 pm

Title: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on February 23, 2007, 07:44:06 pm
Hi Guys

I picked up a 2005 model KLR650 in PE for a good price, but it needs some work to be perfect again.

Since there are so many KLR owners on this website i was wondering if you guys could give me a few answers.

The bike has done 43000kms but mostly on tar so its quite neat.

What would the following replacements cost me?

1. Front tyre? What should i buy, bike will mostly run on tar and good gravel.

2. Front and rear brake disks and pads? The current units are still working but they are worn.

3. Front and rear sprockets and chain? What should i buy? The chain is a bit slack and the sprockets worn quite deep.

4. Leaking front shock? What would the replacing of the seals cost?

Thanks
Captain Slow
Title: KLR650 Restoration....Please help......
Post by: shark_za on February 23, 2007, 07:52:21 pm
All basic maintenace items, should not cost too much, although doing it all at once adds up.

For a chain and sprocket, any 520 o-ring chain, probably about R400.
Sprockets, from Kawa, check for new pricing.

Do your disc's really need replacing? Or just the pads?
Pads are cheap, say R80-R100 for each brake.

I like a more offroad tyre, but for lots of road look at the Trailwings.
Fronts are cheap, expect to pay around R400-R500.

Fork seals, not sure on price, but reasonably cheap.
Title: KLR650 Restoration....Please help......
Post by: sidetrack on February 23, 2007, 08:54:29 pm
Don't skimp on the chain, buy a good o or X ring otherwise expect to adjust it every other ride or worse it snapping like LouisXander's did  :shock: Oh yeah and congrats, let us see a pic of your KLR !
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 23, 2007, 10:19:45 pm
I'll post some pics tomorrow. If everything goes allright.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 24, 2007, 01:55:44 pm
Part Description   Cost
Front sprocket   R 120.00
Rear sprocket   R 220.00
O-ring chain   R 450.00
Fork seals   R 160.00
Front disk   R 1,470.00
Rear disk   R 940.00
Brake pads front   R 180.00
Brake pads rear   R 180.00
Spark plug   R 20.00
Air filter   R 250.00
Front tyre Bridgestone Trail wing   R 480.00
Rear tyre Bridgestone Trail wing   R 650.00
Labour 3 Hours   R 600.00
Total   R 5,720.00

These prices are all from a Kawa dealer, except the tyres.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 24, 2007, 02:15:57 pm
(http://w2.bikepics.com/pics/2007/02/24/bikepics-810933-full.jpg)
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on February 24, 2007, 03:30:58 pm
Hey Captain KLR?

You could easily save yourself the R600 labour by finding someone (from the forum?)  who is familiar with working on bikes.
Believe it or not most of the stuff you want to replace is a fairly simple operation.
But you will need someone who has done this kind of work on bikes before.
I am assuming you have not?

How badly are the sprockets worn?
When they wear the points of the sprockets lean forwards in the direction of wheel travel.

You probably don?t need to replace the discs mate, just the brake pads.
Hard to imagine the dics are already worn thru on a 2005 model?

Perhaps you could find a forum member who is familiar with the KLR and lives near you?
Run the bike over to his place and get a second opinion for the stuff that needs to be replaced?
I am not making a comment on SA bike shops?but it?s obviously to a shops advantage to point out things that are worn on a bike and suggesting those things need to be replaced.
I am not saying they do not need replacing, but perhaps some of those parts may last for a few months yet.
I understand that the brakes on a KLR are nothing to get excited about, even when they are brand new.
Remember you are coming off a sports bike?which  probably had far superior brakes.

The front fork seal will need to be replaced however.
Make sure you change the oil in the forks, people leave the fork oil in bikes for far too long.
Some nice clean oil will make a world of difference.

Air Filter...get a UNI-Filter...they are made to be washed and used many times over. I am sure they make one for the KLR.

Front tires last a lot longer than rear tires, you also don?t need a super expensive one for the kind of riding most KLR owners would do.
Bridgestone normally have some very cheap tires, I use them on my own bikes.

I really reckon you need another trail bike owner to have a look and advise you about the things on your list that need replacing mate.

Pity I?m not in SA yet?I would have done all the work on the bike for you mate.
One full day would probably see it all done.

You should also change the engine oil, and install a new egine oil filter.

You just need the tools and someone who is used to working on his own trail bike.
DON?T attempt the work yourself if you have absolutely no idea what you are doing.

Once you have helped someone change chains and sprockets, it?s easy.
Same for discs and brake pads.
Etc.

Hope some of this helps.
Sure a few blokes on the forum have suggestions also.

Cheers: Jaq. (also a SA KLR owner apparently.)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 24, 2007, 04:15:58 pm
Hi Jaq

Go look on the BikeSA forum, i have touble posting pics here.

There is a pic of the sprocket.

The chain is screwed man. I'll rather replace now while i have the money.

Disks, i'm only replacing the front disk and pads. The rear is okay.

Yes i am used to the single finger stopping ability of the Gixxer that i had. But i still want to see if the new disk and pads won't make it better. The bike has done 43 000kms on tar remember. It really needs new front brakes. The disk has about a millimeter groove on each side and in between there are smalle grooves. Almost like its been metal on metal. You know what i mean.

The fork seals i'm gonna get done at the shop as i dont have all the tools for the job. I will put new oil in.

As to mechanical work. I've got quite alot of experience with that. I'm an engineering student remember. Its just that i've never worked on bikes before.

I allready ordered, front and rear prockets and chain. Front disk and pads. Fork seals.

I'll have a look later on the disk and pads and even sprocket and chain i'm considering to do myself. But i don't know about the fork seals.

Thanks for the info Jaq
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on February 24, 2007, 04:26:43 pm
I'm just off to bed, 0100 hrs here.
But I'll pop over to bikersa and have a gander at ya post.

Chains and sprockets are dead easy to replace (so long as none of the bolts or allen screws wear away when you're un-tightening them).

You may need a chain breaker and a master link.

Again I reckon a forum member probably has a chain breaker he could lend you.
You can also grind the chain plates away on a grinder. Watch ya fingers and eyes.

(And here the BMW GS owners all shout..." I've got shaft drive, don't need to deal with no dirty, oily, greasy chains!" ) :D

I agree it may be better to get a shop to do the fork seals, can be tricky if there are bolts to be undone in the lower fork legs.
(Al la BMW) :D

Let us know how ya go mate.

Cheers and good night/morning.
(Takin Lin trail biking tommorow, so up early for that.)
Title: congrats
Post by: bobnob on February 24, 2007, 10:07:45 pm
congrats on the bike!!!

with regards to the new disc i would say see if you can have it schemed

if the groves are not to bad a good enginering place will scheme it out nicely

otherwise have an enginering shop make you one (much cheeper) and spend the money you save on braded hoses front and back - apparently it makes a huge difference

i know exactly how you feel

my tt600 stops like a train with bicycle brakes - 2 drum brakes  :roll:
Title: KLR650 Restoration....Please help......
Post by: Groenie on February 25, 2007, 08:11:32 am
Good news and congrats Captain. Sorry we missed each other when we were down there. You should do all the work or as much as possible, yourself. That way you get to know your bike and find all the other little things you missed on the first inspection. Remember Locktite is your KLR's best friend. The bike is a winner in the weight loss department, everything rattles loose after a few K's.

Check for a engineering shop in your area that can cut a new front disk for you. They wil charge you around R600 for it. The rest is easy, even the fork seals. You might have to fabricate a special tool to take the shock apart though, but being an engineering student, I'm sure you can weld?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 25, 2007, 12:41:51 pm
What kind of Loctite should i use?

I'm going to see how much time i have and then do what i can.

Groenie, I agree with you i should do most of the work myself.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 25, 2007, 12:48:08 pm
I found two more items that needs replacement.

Front indecator housing.

What should i do to fix this cheaply? I was thinking of glue, but some of the pieces are missing.

Broken spoke on the rear rim.

A friend of mine was driving behind me when i fetched the bike and told me that the rear had a slight buckle, when i got home is saw one spoke is missing. Thats probably what caused the buckle. From my cycling years it wasn't that difficult to replace a spoke and straighten a rim. How difficult is it on a KLR? The wheels will have to come off for new tyre anyway.
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on February 25, 2007, 01:49:50 pm
Front indicator housing...do you guys have bike wreckers in SA?

Many here. They normally have a whole boxload of indicator housings for most model bikes.

I was thinking you could get the discs from a wreckers actually.
Even the chain and sprockets if they are wrecking a complete bike and they are in ok condition.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 25, 2007, 01:59:41 pm
Quote from: "Jaqhama"
Front indicator housing...do you guys have bike wreckers in SA?

Many here. They normally have a whole boxload of indicator housings for most model bikes.

I was thinking you could get the discs from a wreckers actually.
Even the chain and sprockets if they are wrecking a complete bike and they are in ok condition.


The parts that i ordered is still part of the original budget that i put out for repairs so thats fine.

I'll rather put new stuff on.

Jaq, you made me think again.  :D

I'm still going to buy new chains and sprockets, but i'm gonna store them till i really need them. I'm going to take off the old chain clean it properly and lube it again, refit and adjust. It should easily give me another 5000kms.
Title: KLR650 Restoration....Please help......
Post by: D7 on February 25, 2007, 03:49:24 pm
yo keptin

before shark goes on about the red ones being faster,  let me warn you.

it is nonsence.   the green ones are a tad quicker and a shirt load better looking!!!!!

on the up side - you got the right bike!!!!!!!!!!!!!!
may you have many  :D miles upon her

salut!
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 25, 2007, 04:01:10 pm
Quote from: "D7"
yo keptin

before shark goes on about the red ones being faster,  let me warn you.

it is nonsence.   the green ones are a tad quicker and a shirt load better looking!!!!!

on the up side - you got the right bike!!!!!!!!!!!!!!
may you have many  :D miles upon her

salut!


I got 150km/h on the clock yesterday. :D
Title: KLR650 Restoration....Please help......
Post by: KiLRoy on February 25, 2007, 11:41:54 pm
Speak to Rooibaard in the shop section - he's breaking his KLR up for spares

H
Title: KLR650 Restoration....Please help......
Post by: Watty on February 26, 2007, 10:03:05 am
Lots of info, maintenance tips, diagrams/photo's. FAQ, etc. available at these sites for the KLR650.  Especially the first two sites are invaluable reference sources for any KLR owner!  8)

1. KLR 650 FAQ (http://www.bigcee.com/klr650faq.html)
2. Kawasaki KLR 650 Forum (http://www.klr650.net)
3. MarkNet - KLR650 : Doohickey Replacement (Idler Shaft Lever) (http://www.klr650.marknet.us/doohickey.html)
4. Conalls KLR650 Website (http://www.angelfire.com/co/klr650/index.html)

Enjoy!  :roll:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 26, 2007, 12:35:05 pm
Thanks for the info.

Greatly apreciated.  :D
Title: KLR650 Restoration....Please help......
Post by: lecap on February 26, 2007, 01:03:36 pm
I have Eagle Lever Doohickey replacements in stock and sell them as well as fit them. You should find out if your bike is still running on the original doohickey. After 40odd thousand km this might be a reason to worry.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 26, 2007, 04:21:58 pm
Quote from: "lecap"
I have Eagle Lever Doohickey replacements in stock and sell them as well as fit them. You should find out if your bike is still running on the original doohickey. After 40odd thousand km this might be a reason to worry.


I'll look into it. Thanks for the warning.

Allthough i don't know what a doohickey is yet. The guys forwarded me the links i'll check it out later. How much is a doohickey and is it difficult to fit?
Title: KLR650 Restoration....Please help......
Post by: lecap on February 27, 2007, 02:30:12 pm
Not sure yet but I think the whole job with parts will be around R 1000.

To DIY you need some special tools. Not so much special skills. A good hobby mechanic with a good quality tool kit can do it.
You need a flywheel holder and a flywheel puller to get the generator flywheel off and on.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 27, 2007, 09:20:17 pm
Guys i picked up one more problem with the KLR. When i go through a really bumpy section of road the handle bars vibrate. Could this be worn steering bearings. Okay don't laugh i don't know what you call those bearings but i know they are used to make the bike turn smoothly.

Also i found the big nut underneath the handle bars in the middle is a bit loose i tightened it by hand. Could this nut cause the vibrations?

How tight should i make that nut?
Title: KLR650 Restoration....Please help......
Post by: shark_za on February 28, 2007, 01:06:05 am
oh yes, classic hassle.
Size 27 socket. maak vas.

Swap your bars for Pro Taper SE ATV Hi, work for me, KiLRoy, Wilhelm, D7 too I think.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 07:58:11 am
Quote from: "shark_za"
oh yes, classic hassle.
Size 27 socket. maak vas.

Swap your bars for Pro Taper SE ATV Hi, work for me, KiLRoy, Wilhelm, D7 too I think.


If i tighten the nut will it stop the vibration? Hmm i guess i'll have to see.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 08:27:31 am
Could somebody please explain to me what the function of the cable operated switch is thats connected to the kick stand.

The previous owner mumbled something about tampering with the switch.

Can i disable the switch? What would the effects be?

Yes i know i ask lotsa questions but i want to get the bike sorted before the end of March.

Thanks for the help so far.
Title: KLR650 Restoration....Please help......
Post by: lecap on February 28, 2007, 08:28:16 am
I think shark_za refers to the big hex nut on top of the triple clamp. If it is loose you can just tighten it (assuming the triple clamp - bearing assembly was fitted and adjusted correctly)

If you tighten the round slotted nut beneath the triple clamp you will overtighten your steering head bearing and most probably see your arse trying to negotiate the next corner.
Setting a steering head is not a beginners game especially with the slightly tricky setup of the KLR's bearings & upper triple clamp. (Hail to the old Honda double slotted nut with locking washer system!)

Never ever trust "recipes" to set steering heads. It needs to be free of any play and it needs to be precisely that. Don't try to supplement torque wrenches and angles for feel and experience.

Get your steering head bearings checked. They are most probably stuffed up already.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 08:34:25 am
Thanks Le Cap. I'll try to tighten the nut first and see the effects.
Title: KLR650 Restoration....Please help......
Post by: lecap on February 28, 2007, 08:39:35 am
Do NOT disable the side stand switch.
It's an important safety feature preventing you to ride the bike with its side stand down.

The cable connecting the side stand to the switch easily lasts some 3 to four years and only costs a few Rand. Take it out once a year and flush it with Q20.
If the cable should seize in the sleeve while you are on tour you simply remove the black plastic cover that protects the switch and alternator wiring harness and pull the switch into the "side stand up" position by hand once the side stand is up. Do not disconnect the cable. You will kep the safety feature and get home without problems.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 08:56:01 am
Okay Le Cap i won't disable the switch, but there is something wrong with mine.

This morning the starter was dead. The stand was still down. So all i did was kick the stand up and the bike started. Then i let the stand down again to let the bike idle.

What i don't understand is sometimes the bike starts with the stand down and sometimes it won't and visa versa. I think the cable is could be stuck. What do you think?
Title: KLR650 Restoration....Please help......
Post by: IDR on February 28, 2007, 09:06:32 am
Quote from: "Captain Slow"
Okay Le Cap i won't disable the switch, but there is something wrong with mine.

This morning the starter was dead. The stand was still down. So all i did was kick the stand up and the bike started. Then i let the stand down again to let the bike idle.

What i don't understand is sometimes the bike starts with the stand down and sometimes it won't and visa versa. I think the cable is could be stuck. What do you think?


I have the same problem on my Z750  :?
Title: KLR650 Restoration....Please help......
Post by: JourneyMan on February 28, 2007, 09:11:28 am
Quote from: "InsiderDirtRider"
Quote from: "Captain Slow"
Okay Le Cap i won't disable the switch, but there is something wrong with mine.

This morning the starter was dead. The stand was still down. So all i did was kick the stand up and the bike started. Then i let the stand down again to let the bike idle.

What i don't understand is sometimes the bike starts with the stand down and sometimes it won't and visa versa. I think the cable is could be stuck. What do you think?


I have the same problem on my Z750  :?


High probability that it is the cable. Most probably dirt causing the cable to mis-behave.

Happened on the DR with the KLR.
Title: KLR650 Restoration....Please help......
Post by: IDR on February 28, 2007, 09:12:57 am
Quote from: "JourneyMan"
Quote from: "InsiderDirtRider"

I have the same problem on my Z750  :?


Most probably dirt causing the cable to mis-behave.


Somehow I don't think dirt is causing the problem...Z750s aren't too happy off-road  :D
Title: KLR650 Restoration....Please help......
Post by: JourneyMan on February 28, 2007, 09:17:21 am
Quote from: "InsiderDirtRider"
Quote from: "JourneyMan"
Quote from: "InsiderDirtRider"

I have the same problem on my Z750  :?


Most probably dirt causing the cable to mis-behave.


Somehow I don't think dirt is causing the problem...Z750s aren't too happy off-road  :D


What's a Z750? hehe :oops:  :D

Was referring to the KLR. :wink:

Mis-quote. :oops:
Title: KLR650 Restoration....Please help......
Post by: IDR on February 28, 2007, 09:35:51 am
Quote from: "JourneyMan"
What's a Z750? hehe :oops:  :D

A road bike:
(http://www.phmotorcycles.co.uk/bikes/images/kawasaki/Z750S.jpg)

Quote from: "JourneyMan"
Was referring to the KLR. :wink:


The KLE's side-stand thingy came off going up Sani - it's now happily cable-tied to the frame out of harm (and the side stand)'s way  :D
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on February 28, 2007, 09:41:41 am
Are the KLR 650's handlebars rubber mounted?

They are on my Dominator and they vibrate noticibly quite a bit when riding over corrugagtions.

I took them off my old Domi and replaced with stainless washers, much better.

I find the handlebars on my mate's KLR 650 more comfortable than the ones on my new Domi...I would leave the original KLR bars on the bike myself. (Just my opinion.)

Side-stand cut out switch; they stop me starting some of my bikes when the stand is down, even if the bike is in neutral, so now I always disconnect them.
Pain in the arse I reckon.
Almost as good an idea as self-retracting side stands. :roll:
Title: KLR650 Restoration....Please help......
Post by: MrBig on February 28, 2007, 09:44:20 am
Quote from: "Captain Slow"
Okay Le Cap i won't disable the switch, but there is something wrong with mine.

This morning the starter was dead. The stand was still down. So all i did was kick the stand up and the bike started. Then i let the stand down again to let the bike idle.

What i don't understand is sometimes the bike starts with the stand down and sometimes it won't and visa versa. I think the cable is could be stuck. What do you think?


Scuse my ignorance - I don't know a KLR from a bar of soap.

But what you describe sounds more like a clutch switch than a sidestand switch.
If the bike is in Neutral it shouldn't matter where the sidestand is surely? (Unless it's stuffed I suppose)
So what is your starting procedure?
Do you depress the clutch when starting? Or do you start from Neutral?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 09:49:25 am
Quote from: "MrBig"
Quote from: "Captain Slow"
Okay Le Cap i won't disable the switch, but there is something wrong with mine.

This morning the starter was dead. The stand was still down. So all i did was kick the stand up and the bike started. Then i let the stand down again to let the bike idle.

What i don't understand is sometimes the bike starts with the stand down and sometimes it won't and visa versa. I think the cable is could be stuck. What do you think?


Scuse my ignorance - I don't know a KLR from a bar of soap.

But what you describe sounds more like a clutch switch than a sidestand switch.
If the bike is in Neutral it shouldn't matter where the sidestand is surely? (Unless it's stuffed I suppose)
So what is your starting procedure?
Do you depress the clutch when starting? Or do you start from Neutral?


Always start in Neutral. Always depress the clutch.
Sometime stand is down. Sometimes stand is up.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 09:57:29 am
Mr. Big. Clutch switch, what clutch switch? :shock:

Does a KLR have a clutch switch? If so what for? :D
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on February 28, 2007, 09:59:17 am
Different models of bikes have different "safety" cut outs in regards to side stand and neutral.

Some bikes now won't even start in neutral with the stand down.
Some will start in nuetral with stand up, and will continue to run after starting with stand put back down. (My new Domi did this.)

It's why I remove the sidestand cut-out...I am used to starting the bike in neutral on a flat surface and letting the engine warm up, I just can't be bothered with the hassle of having a different procedure for each different bike.
Title: KLR650 Restoration....Please help......
Post by: IDR on February 28, 2007, 10:03:43 am
Quote from: "Captain Slow"
Mr. Big. Clutch switch, what clutch switch? :shock:

Does a KLR have a clutch switch? If so what for? :D


Side-stand switches usually go hand-in-hand with clutch switches - to see whether the clutch is being depressed when starting in gear (so you can't start the bike in gear without having the clutch depressed)...or in some instances, will allow you to start the bike in gear with the stand out, and then cut out the engine when the clutch lever is released.

Triumphs have this silly thing where you HAVE to depress the clutch before the starter will work, regardless of side-stand or gear...  :?
Title: KLR650 Restoration....Please help......
Post by: shark_za on February 28, 2007, 10:06:15 am
The KLR has a clutch and side stand switch that cuts out the starter circuit.

There is some logic sequence it uses, and the sidestand switch often messes with everything making it look the like the clutch switch.
Sometimes you have to "zero" the clutch switch to get it to start when in neutral.

I disabled my sidestand switch, I dont have one on my offroad bike and dont agree that its an essential safety mechanism.

Get on the bike, even in neutral pull the clutch once and release, press and it fires up.
ALWAYS.
With the sidestand switch it would mess up after a long days dirt riding.

Its better to start in neutral with or without clutch as the plates often stick and it labours the starter motor.
Title: KLR650 Restoration....Please help......
Post by: KiLRoy on February 28, 2007, 11:01:16 am
Disabled both my switches - they old time I start they bike in gear just results in half meter lurge and a sqeezed asshole :D  

Jaq - would recommend fitting a Pro-Taper bar - about R450 and made of alu - bit higher too - helps a lot.  Maybe some clutch lever/hand protectors for the odd spill too.  I'll check the bike this weekend at Wino - maybe drain the fork oil and replace with a 10w oil - bit stiffer for 2-up riding.

H
Title: KLR650 Restoration....Please help......
Post by: IDR on February 28, 2007, 11:14:13 am
Quote from: "KiLRoy"
would recommend fitting a Pro-Taper barH


How difficult is it to move grips and stuff over?  it was a BITCH to remove my KDXs grips!!!
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 11:18:35 am
Quote from: "KiLRoy"
Disabled both my switches - they old time I start they bike in gear just results in half meter lurge and a sqeezed asshole :D  

Jaq - would recommend fitting a Pro-Taper bar - about R450 and made of alu - bit higher too - helps a lot.  Maybe some clutch lever/hand protectors for the odd spill too.  I'll check the bike this weekend at Wino - maybe drain the fork oil and replace with a 10w oil - bit stiffer for 2-up riding.

H


I think i should put 10W in mine too.  :D
Title: KLR650 Restoration....Please help......
Post by: Groenie on February 28, 2007, 11:58:46 am
Quote from: "InsiderDirtRider"
How difficult is it to move grips and stuff over?  it was a BITCH to remove my KDXs grips!!!


Get new grips! I already have new green gel grips to go with the Pro tapers when I eventually get them.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 01:32:21 pm
Okay i tightened the big number 27 nut under the handle bars. Hell it was very loose. :shock:

The four alan cap screws that holds the hasdlebars in place were also loose. :shock:

I'll have to go through the bike properly this weekend who knows what else is loose. :shock:
Title: KLR safety features
Post by: lecap on February 28, 2007, 03:36:37 pm
Running the risk to get called a &(%$$%$/($%(% but sometimes it's really tiring to listen to the unqualified advice of hobby mechanics.

Never disable safety features without thinking twice!

The KLR side stand switch will cut out the engine if you put the bike into gear, release the clutch and your side stand is down.
I grew up in the time when Hondas had a little rubber mounted on the side stand which was supposed to push the side stand in if you tried to corner on it. The rubbers wore and tore quickly.
I saw lots of toasties and a number of thrashed bikes.
After they got sued a couple of times I saw Honda replacing all their old side stands with silly automatically retracting ones. Free of charge.

Since then every bike comes with a side stand switch.

The little trouble the KLR side stand switch can give is easily cured, takes one minute with a phillips screwdriver on the side of the road. See my post above.
Keep the cable in good working order and you will never have trouble.

The clutch switch is a different story. It will cut the connection from the start button to the starter solenoid if you are in gear unless you pull the clutch.
The clutch switch gives trouble without ends as it seems to have a build in dust magnet.
There is an easy way to cure the problem:
You can disassemble, clean, assemble and adjust the little bugger every few days of riding. Takes two minutes.
If the trouble starts during a day of riding you put the bike into neutral, press and hold the starter button and wiggle the clutch lever until you find a position where the switch closes (there is always one).

You can bridge the clutch switch allowing the bike only to start in neutral. It will then cut out immediately if you put it into gear with the side stand down.

If you tamper with the clutch switch bridging it completely or if you disable the side stand switch you will be able to ride the bike with its side stand town and thus be able to kill yourself.

Have fun!
Title: KLR650 Restoration....Please help......
Post by: lecap on February 28, 2007, 03:45:42 pm
Maybe I should write a post about suspension tuning?

Heavier fork oil does NOT sort out a soft front end.
It only turns a undersprung front end into an undersprung and overdampened front end. (Which is worse)

You can increase the spring preload with spacers. Note that this does not make a spring harder!!!
You can add air (if your forks allow) which adds preload and a little bit of progression.
You can add oil which adds a lot of progression.

All three measures have their limits. Too much spring preload will damage your springs and too much air or oil will pop your fork seals.

The way to go is to throw your fork springs away and get decent ones.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on February 28, 2007, 03:49:46 pm
Thanks for the info Le Cap.

I won't disable my switches as they are there for a reason and if the bike won't start now i know where to look.

I checked my side stand switch and cable it seems to be working right.

The clutch switch.... Where is it located?
I wanna have a look at it.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 01, 2007, 08:41:18 am
The clutch switch sits underneath the clutch lever assembly on the handlebar. It's bolted onto the assembly with two small phillips screws. If you loosen the screws a turn you can adjust the position of the switch (which often sorts out problems).
Be careful when you take it off as there is a little slider and a spring inside. They usualy stay in place but love to disappear into nowhere on grassy camp sites, graveled driveways or in messy garages :-)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 01, 2007, 09:20:57 am
Quote from: "lecap"
The clutch switch sits underneath the clutch lever assembly on the handlebar. It's bolted onto the assembly with two small phillips screws. If you loosen the screws a turn you can adjust the position of the switch (which often sorts out problems).
Be careful when you take it off as there is a little slider and a spring inside. They usualy stay in place but love to disappear into nowhere on grassy camp sites, graveled driveways or in messy garages :-)


Ahhh found it. I think all my switches are actually working. I just got paranoid when the bike wouldn't start. It starts fine now.  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 01, 2007, 09:46:11 am
First day with the KLR.

Notice the Suzuki Jacket.

(http://w2.bikepics.com/pics/2007/03/01/bikepics-816133-full.jpg)
Title: KLR650 Restoration....Please help......
Post by: macduff on March 01, 2007, 09:56:05 am
aha, the jacket....
explains the nick - captain slow  :D
Title: KLR650 Restoration....Please help......
Post by: D7 on March 01, 2007, 10:05:04 am
now remember keptin

it aint purdy till it's dirty!!!!!!!!!!!!
Title: KLR650 Restoration....Please help......
Post by: FreeFlight on March 01, 2007, 10:25:41 am
Hi Cap,

Visit www.klr650.marknet.us
This guy has done a lot of maintenance articles on the KLR, I do all my own maintenance after the stealer did absolutely nothing on my bike when it went in for its service. Came back to me with a loose steering and vavle clearence on the inlets that was below spec!

Loctite..... I use contact adhesive on most of the bolts\screws, keeps them in and you don't struggle or strip their heads when you have to take them out again. Use loctite only on the engine bolts, cause you don't remove them that often.

I would also take the rear suspension apart and grease the whole thing, if you do this you can easily remove the chain to replace\clean.
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 01, 2007, 11:26:13 am
Quote from: "KiLRoy"
Disabled both my switches - they old time I start they bike in gear just results in half meter lurge and a sqeezed asshole :D  

Jaq - would recommend fitting a Pro-Taper bar - about R450 and made of alu - bit higher too - helps a lot.  Maybe some clutch lever/hand protectors for the odd spill too.  I'll check the bike this weekend at Wino - maybe drain the fork oil and replace with a 10w oil - bit stiffer for 2-up riding.

H


It should have 10 weight in it already yeah?

But I encourage changing it..makes a big difference.
You should have seen the prehistoric tar substance that came out of the forks on my Domi when I first bought it. :shock:

15 weight is too heavy.

My KLR already has plastic brush protectors yes?
They'll do.
I'll just take a spare clutch lever with me. :D
Standard handlebars suit me, changing the handlebars isn't going to make me a better rider. :lol:

Thanks very much for going over to Wino's and doing a few things to the bike mate.
I am much obliged.
I will need a bracket to keep my new nylon saddlebags off the right side muffler.

Cheers: Jaq.
Title: Re: KLR safety features
Post by: Jaqhama on March 01, 2007, 12:08:44 pm
Quote from: lecap
Running the risk to get called a &(%$$%$/($%(% but sometimes it's really tiring to listen to the unqualified advice of hobby mechanics.

Meaning that one should only listen to and take the advice of a 100% trained, certified, licenced motorcycle mechanic?
As opposed to riders who have lived and breathed bikes all their lives and know their own bikes inside and out?
They just don't happen to have a bit of paper which says they are qualified?


Never disable safety features without thinking twice!

I agree, one should always consider the results of ones actions.



Since then every bike comes with a side stand switch.

Not so...I just bought a brand new DT 175 Yamaha...kickstart only, no side stand cut out switch.
Did you mean every Honda or every bike with auto-start?


If you tamper with the clutch switch bridging it completely or if you disable the side stand switch you will be able to ride the bike with its side stand town and thus be able to kill yourself.

There are hundreds of thousands of riders all over the world riding older model bikes that did not come with a side stand switch.
Few of my bikes have ever had the side stand switch.

I guess older riders or riders of older machines must just be smarter huh?
They can remember to flick up the side-stand before they take off.
:roll:

And before everyone younger than guys like me and KilRoy and Shark have a huge panic about leaving the side-stand down...9 times out of 10 it will hit the ground and flick up anyway if you've forgoten to put it up.
A bike moves forwards...the side stand moves backwards.
Some hobby mechanic must have thought of that years ago.
:D
You will also hear a rather odd scraping noise...which usually alerts one to the fact that one has  been remiss in one's stand-flicking -up-duties.
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 01, 2007, 12:49:10 pm
Quote from: "lecap"
Maybe I should write a post about suspension tuning?

Heavier fork oil does NOT sort out a soft front end.
It only turns a undersprung front end into an undersprung and overdampened front end. (Which is worse)

You can increase the spring preload with spacers. Note that this does not make a spring harder!!!
You can add air (if your forks allow) which adds preload and a little bit of progression.
You can add oil which adds a lot of progression.

All three measures have their limits. Too much spring preload will damage your springs and too much air or oil will pop your fork seals.

The way to go is to throw your fork springs away and get decent ones.


Well I don't disagree with any of the above.
But I do look at the last statement in a different way...

You mean the bike manufacturers don't put decent fork springs in their bikes to begin with?

And that one should straight away go out and purchase expensive aftermarket springs?

Look, lets be honest here yeah...for the majority of riders who are not professional, or even gifted amateur riders, the springs that come as standard with the majority of trail bikes (and even most road bikes) are perfectly fine.

Now as most people here ride what we're starting to term "adventure bikes" I don't believe that they need anything more than the normal fork springs in their bikes...unless A: They have ridden thousands of kilometers of rough roads and the springs are just completly buggered.
B: they ride hard and fast over rough terrain constantly and due to the speed and road/trail conditions the forks that come as standard just aren't coping with the abuse.

If the latter is the case then I would suggest that they should be looking at a hardcore off road bike instead of an adventure tourer in the first place.
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 01, 2007, 01:26:14 pm
I changed the springs in mine, I do use my KLR for a little bit more than the average adventure rider and wanted the improved performance.
Title: KLR650 Restoration....Please help......
Post by: KiLRoy on March 01, 2007, 03:01:59 pm
I may be an unqualified mac, but everything I did on my bike was after good research and lot of q&a sessions with people on KLR650.net - they live KLR's from the late 80's not only for the past 3 and half years like me - after the first A-model was imported.  So some facts:

Disable safety features:  IMHO the are more of a irritation than a safety feature - the are prone for trouble - all RTW riders on KLR's disabled or bridge theirs

Fork oil: The KLR come out with 'fish-oil' in its already vulnerable forks - replace them with any new oil for a better ride - try it it works.  Most people use anything from 7w-12w oil - depending on use and rider weight.  I've settled for 10w and think its a good compremise for my needs.  More off road rider will have a lighter oil with better springs and maybe a cartridge emulater.  I've bought Progressive springs with 190ml 10w oil and 60mm spacers.  Can't do much worse.  A cheap option is just to replace the oil with 10w for a bit better ride and less sag.  This i did in conjuction with Tro-taper bars - mainly because its higher but also because the alu helps with vibes - Acerbis guards to protect hands and helps with protection and gel grip - feels good and lessen vibes.

ITO stability I also added a Happy Trails H2 fork-brace - no more drifting, tank slappers, wild handle movements at any speed.  As stable as a KLR can gets at speed...

I've done a lot of other mods - mainly because I like to and because the all serve a purpose - from T-mod vents, alu skidplate, ss braided front brake lines, rad/res protection, UNI and Twin Air filters etc etc

As a qualified mac, what have you done to improve the KLR, and how long do you own a KLR?

Hein

Ps:  Baie kak ook aangejaag - meestal pilot's error :oops:
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 01, 2007, 03:22:02 pm
Quote from: "shark_za"
I changed the springs in mine, I do use my KLR for a little bit more than the average adventure rider and wanted the improved performance.


Yes...I've seen some of your photos. :lol:  :lol:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 01, 2007, 03:49:26 pm
Another issue on the KLR that needs attention.

The front brakes!!!

Let me start by telling you about my rear brakes. Well the rear brake on my KLR is bloody good. It bites sharper than the brake i had on the GSXR. Its actually a bit too sharp. It locks up easily.

I did a few emergency stops on a piece of deserted tar and found that the front dips and then the rear lets go, making a long black stripe down the road usually i can control the skidding of the rear but if cars are doing silly thing in front of me i'm definitely gonna crash.

The front brake has no feel to it. It feels like you are pulling onto a stone. I'm sure almost none of the force applied at the top reaches the caliper. Well thats it there is almost no power in the front.

What i cant understand is why is the back so powerfull but the front so weak. If i could get the front as good as the back i'll be happy.

I ordered a new front disk and pads from the stealer and i will probably put some new brake fluid in the system.

O yes i ordered the parts on Saturday the oke said no problem sir you'll have the parts in two working days. I'm still waiting.
Title: KLR650 Restoration....Please help......
Post by: JourneyMan on March 01, 2007, 03:54:04 pm
Quote from: "Captain Slow"


Let me start by telling you about my rear brakes. Well the rear brake on my KLR is bloody good. It bites sharper than the brake i had on the GSXR. Its actually a bit too sharp. It locks up easily.



Those knobblies respond/act way different than the tyre you had on the GSXR.

On the very first hardish brakes I did after I replaced the Tourance with Kenda at the back,  I was shocked with the ease with which the Kenda let go under the same braking conditions as the Tourance (on tar). Maybe this is what you are experiencing? :?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 01, 2007, 04:01:43 pm
Quote from: "JourneyMan"
Quote from: "Captain Slow"


Let me start by telling you about my rear brakes. Well the rear brake on my KLR is bloody good. It bites sharper than the brake i had on the GSXR. Its actually a bit too sharp. It locks up easily.



Those knobblies respond/act way different than the tyre you had on the GSXR.

On the very first hardish brakes I did after I replaced the Tourance with Kenda at the back,  I was shocked with the ease with which the Kenda let go under the same braking conditions as the Tourance (on tar). Maybe this is what you are experiencing? :?


Yes i've got a serious offroad tyre on the back which i will replace with a tyre more suited to tar. But the problem still lies with the front brake.
Title: KLR650 Restoration....Please help......
Post by: D7 on March 01, 2007, 04:17:25 pm
unfortunately about the only cost effective thing you can do to make the front better is to put on a stainless steel brake hose.   It makes a subsstantial difference,  but you'll never have the brakes you want
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 01, 2007, 05:00:58 pm
Leave more space between you and the car in front. :D

Flushing clean brake fluid thru the system sounds like a good plan also.

And I believe we're all in agreement about the braided cable.
(Nodding wisely here.)

Having said that I've had lots of trail bikes and it's just something you get used to.

If you've got lots of spare bucks I guess you can get a custom brake conversion done, get the disc from a Jap sports bike put on.
Plenty of motard guys do I suppose.

But then you could get into a lot of trouble off road.

Six of this and half a dozen of the other.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 02, 2007, 08:39:27 am
Quote from: "Jaqhama"

...But I do look at the last statement in a different way...

You mean the bike manufacturers don't put decent fork springs in their bikes to begin with?

And that one should straight away go out and purchase expensive aftermarket springs?

Look, lets be honest here yeah...for the majority of riders who are not professional, or even gifted amateur riders, the springs that come as standard with the majority of trail bikes (and even most road bikes) are perfectly fine.

Now as most people here ride what we're starting to term "adventure bikes" I don't believe that they need anything more than the normal fork springs in their bikes...unless A: They have ridden thousands of kilometers of rough roads and the springs are just completly buggered.
B: they ride hard and fast over rough terrain constantly and due to the speed and road/trail conditions the forks that come as standard just aren't coping with the abuse.

If the latter is the case then I would suggest that they should be looking at a hardcore off road bike instead of an adventure tourer in the first place.


Let me formulate that differently:
If you are not happy with the performance of your bike's front fork the (not too expensive) replacement of the fork springs with aftermarket springs is the most promising way to go.
This is 100% true for the KLR (KL650A)
There is no need to replace the fork springs on every KLR or every bike.

Many bikes come with setups that suit an average rider under average conditions but that does not mean they are perfect.
No one needs a hardcore off road bike because his DS bikes fork is a bit soft.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 02, 2007, 08:47:24 am
There is actually another way to upgrade the front brake.
Have a look at the KL650C: Same disc, different twin piston caliper.
While the brake is not as effective as for example the one on the DR650SE or MZ Baghira it is lots better than the KL650A brake which keeps reminding me of my time on old XT's and XL's (those with drum brakes :-)

I am not 100% sure if the master cylinder on the KL650A and KL650C are identical (but I think they are). Will check that later today.
I will find out a price for a KL650C front caliper and will give you a price for a conversion kit (incl. steel braided hose).
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 02, 2007, 08:50:53 am
Quote from: "lecap"
There is actually another way to upgrade the front brake.
Have a look at the KL650C: Same disc, different twin piston caliper.
While the brake is not as effective as for example the one on the DR650SE or MZ Baghira it is lots better than the KL650A brake which keeps reminding me of my time on old XT's and XL's (those with drum brakes :-)

I am not 100% sure if the master cylinder on the KL650A and KL650C are identical (but I think they are). Will check that later today.
I will find out a price for a KL650C front caliper and will give you a price for a conversion kit (incl. steel braided hose).


Ahh thanks man.

Will it fit on my front shock bracket.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 02, 2007, 08:58:34 am
Allthough i complained alot about the brakes on the KLR i'm starting to get used to them now.

I think when i fitted the new disk, pads and fluid i'll be happy. Maybe is should get that stainless line. I'll see.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 02, 2007, 09:01:46 am
And let me get one thing straight:
I don't mind if anyone disables safety features on his bike and is smart enough to fold his side stand up before riding off.

But I think it's questionable to write on an internet forum that the KLR's side stand switch and clutch switch are prone to give trouble (this is only partially true for the clutch switch) and that it's best to disable them.
For the side stand switch I gave the procedure to sort out trouble with a sticking cable without loosing the safety feature earlier in this thread.
The procedure for the clutch switch is clean and adjust.

None of the two safety switches will leave you stranded on the side of the road should they go whacky. At least not if you have the knowledge and skill to disable them.
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 02, 2007, 09:10:13 am
I would lean and lube the cable of the sidestand switch often, but riding in mud and riverbeds most weekends would have the thing gunking up every 2nd week.
It became a pain to always stop and clean the switch.

So while I have left the clutch as is, the sidestand switch is disabled on my bike.

I'm not even going to compare the hobby mechanic to the pro mechanic, my experience in that has been less than satisfactory.
This is why I service my bike myself.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 02, 2007, 09:11:00 am
Quote from: "KiLRoy"

...As a qualified mac, what have you done to improve the KLR, and how long do you own a KLR?...

I have owned 8 KLR's. Six KL650C and two KL650A. At the moment I own three KL650C and two KL650A. I always was quite happy with the KL650C and did no major modifications to the bikes.
Tried the C's brakes on an A. Nice. Busy checking for price of a possible conversion kit.
I do all service and repairs on my bikes including engine rebuilds.
Title: Re: KLR safety features
Post by: lecap on March 02, 2007, 09:33:39 am
Quote from: "Jaqhama"

There are hundreds of thousands of riders all over the world riding older model bikes that did not come with a side stand switch.
Few of my bikes have ever had the side stand switch.

I guess older riders or riders of older machines must just be smarter huh?
They can remember to flick up the side-stand before they take off

And before everyone younger than guys like me and KilRoy and Shark have a huge panic about leaving the side-stand down...9 times out of 10 it will hit the ground and flick up anyway if you've forgoten to put it up.


Since the early 1980's you will not be able to homologate a bike for road use in Europe or the US if its side stand does not flick up once the weight of the bike is taken off it (Guzzi's famous "knuckle knocker" and the replacement units retrofitted to millions of older Hondas in Europe and the US). Alternatively the bike might have an electric feature (=switch) preventing the bike to be ridden with the side stand down.

I actually thought this is a worldwide standard. My sincere apologies! I did not think that South African bikers are smart enough to get away without those gizmos. Or maybe they only lack the financial power and / or legal tools to sue the manufacturers?

I lived through the tenth out of ten: Highsided my beloved CB550F2 Super Sport causing considerable damage to my previously pristine and original paint job tank and also previously pristine 4-1 can:
I (illegaly) used the old "rubber block" side stand and only put the flick up retrofit on for biannual roadworthyness tests.
The physical pain suffered was rather minor and limited to bruises thanks to my leathers.
The damage inflicted to my ego was beyond imagination as I had some 200 bikers watching (probably 30+ of them knowing me)
Kept the rubber block side stand with self made cut off switch added.

Now you can call me a wimp.
Title: KLR650 Restoration....Please help......
Post by: MrBig on March 02, 2007, 09:57:00 am
Quote from: "shark_za"


I'm not even going to compare the hobby mechanic to the pro mechanic, my experience in that has been less than satisfactory.
This is why I service my bike myself.


 :?
Not quite sure in which of those catagories you place yourself with that statement Shark? :lol:

Myself? Definately a 'hobby' mechanic. At what point would you classify yourself as a pro? When you do it for a living?
Or when you complete a couple of courses? Or do you think experience is what counts?
I can't help but think back to the days as a 15 year old overhauling my 50cc MTX with 3 spanners a pair of pliers and some bloudraad on the back lawn.:shock:
Ok, I didn't use any bloudraad. :lol:

Fact is, I dont trust just any spanner jockey with my ride.
Too many times have I picked up on kak work after (in good faith) using 'accredited' workshops. Professional my ass.
The attention I'm putting into the details can NEVER be matched by anybody who does it for no other reason than getting paid for his time.

You don't need any skill to work on motorbikes. Just patience. And lots of it.
Some decent tools might help.:lol:

Regardless, I'm pretty certain I know my own limitations.
And thats another important part.

I thus say it with pride:
My name is MrBig and I'm a hobby mechanic..
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 02, 2007, 09:57:57 am
I like this thread.

I try to fix up my KLR.

People fighting about safety switches.

Le Cap that brake conversion sounds very interesting.

Carry on guys its very entertaining. :D
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 03, 2007, 03:31:23 am
Some of us took umbrage at Mr Lecap's slur regarding unqualified hobby mechanics mate.

I agree with Mr Big...I have paid good money to have bike shop mechs do less than a stirling job on my sleds.

It's also true that you don't need to be a rocket scientist to do a lot of the work on bikes yourself.

But this is good stuff being written here Captain...you are getting different views on things, that is useful.

As regards different countries having different rules about automatic flick up side stands, stand switches and clutch switches etc etc....yes different countries do have different systems.
In the USA my VLX 600 Honda Shadow had neither an auto flick up stand nor a side stand switch. Had the clutch switch.
Valorie's bike, a brand new 650 cruiser likewise only had the clutch switch.

One of my BMW 650's Boxer's had the flick up stand, the other does not.
The second one only has the clutch switch.
Terri's Ducati only has the clutch switch.

In Oz pop-up stands (if they came with the bike) were normally disabled by the shops selling brand new bikes because they knew riders hated them.

I think most of the bikes being sold brand new in Oz shops today probably do have the side-stand switch and the clutch switch.

This debate is great...everyone's learning something about the switches and the different kinds that bikes come with.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 03, 2007, 08:37:26 am
With "unqualified hobby mechanic" I was not referring to people who fix their own bike and have decent tools, patience, some skill and can eliminate lack of knowledge or experience by using a workshop manual or by phoning a friend who (hopefully :-) knows more.

That's a qualified hobby mechanic!

I started off as one of them and I was working on my own bikes, the ones of neighbours and friends for years before I decided to turn bikes into a career.

As "unqualified hobby mechanic " I would categorize the guy who comes to the workshop and has tried to fix it himself before AND DOES NOT ADMIT IT.
The guy who bought the bike new or perfect condition, services it himself and has dozens of stripped threads fixed with helicoil, all kind of DeLaRey bolts on his bike, 'cause he could not find the originals any more.
Guys who replace gaskets with GunGum and Hylomar.
Or the one who claims that one morning the bike just would not start. And after hours of troubleshooting you find this carbs airscrews tight and the needles sitting atop the slide springs.
The guy with the self made luggage rack with protruding sharp edges.

You have probably guessed that these guys are not fictional ;-)

I have seen lots of profesional and qualified mechanics. Some of them have been living, breathing and talking bikes for decades longer than me.

Others are useless. Unfortunately.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 03, 2007, 09:39:43 am
Le Cap, its so true. You get lots of those guys.
Title: KLR650 Restoration....Please help......
Post by: sidetrack on March 03, 2007, 12:41:30 pm
Riding some nasty terrain may lead to the safety switch on the sidestand cutting the motor, in my opinion it's safer to bypass that switch. I've ridden for over ten years and have never forgotten to put the stand up, now starting in first gear is something we won't talk about  :D
Title: KLR650 Restoration....Please help......
Post by: sidetrack on March 03, 2007, 12:45:21 pm
Quote from: "lecap"

Guys who replace gaskets with GunGum and Hylomar.


Too expensive and messy, breakfast cereal boxes will also work  :twisted:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 03, 2007, 03:37:45 pm
I am still waiting for the bloody parts i ordered from the stealer last week. Since i can't do any major work i bought a plug, some oil and a oil filter.

I took all the covers off the bike and tightened lots of bolts and nuts.

I cleaned the yellow sponge type airfilter with hot water and sunlight liquid. Should i apply some of that airfilter oil in the spray can to the filter before i put it back in the bike? It doesn't look like it had any on the filter when i took it out.

Another question.

How do i get to the plug to change it?

I suppose i have to remove the tank. How do i do it?
Do i have to drain the fuel? Or can i only close the fuel tap and disconnect one of the pipes?
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 03, 2007, 04:20:14 pm
Quote from: "Captain Slow"
I am still waiting for the bloody parts i ordered from the stealer last week. Since i can't do any major work i bought a plug, some oil and a oil filter.

I took all the covers off the bike and tightened lots of bolts and nuts.

I cleaned the yellow sponge type airfilter with hot water and sunlight liquid. Should i apply some of that airfilter oil in the spray can to the filter before i put it back in the bike? It doesn't look like it had any on the filter when i took it out.
Another question.

How do i get to the plug to change it?

I suppose i have to remove the tank. How do i do it?
Do i have to drain the fuel? Or can i only close the fuel tap and disconnect one of the pipes?


Yes mate spray a liberal amount of the airfilter oil on and squeeze it around in the filter.
I normally use clean engine oil myself, and squeeze off the excess.

With the spark plug...not having owned the KLR 650 beofre I am not sure if you have to remove the tank or not.
To take tank off...turn petrol tap OFF...pull rubber hose off tap.
Take off seat, un-bolt petrol tank.

You may have to remove the plastic tank cowling on the KLR.

Buy a fuel filter, cut petrol hose before it goes onto petrol tap, stick the fuel filter on the hose. Filter is a about a dollar.
Helps stop dust and crap in petrol getting into the carbie.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 03, 2007, 07:49:34 pm
Thanks Jaq.

Will be doing the service tomorrow morning.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 04, 2007, 01:39:25 pm
My radiator fan isn't working. Where is the fan fuse located?
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 04, 2007, 02:09:17 pm
Right hand side shroud, by the coolant reservior.
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 04, 2007, 03:42:40 pm
How do you know the fan is not working?

Does it not only come on when the engine gets very hot?
And then turns off again until needed?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 04, 2007, 04:02:04 pm
Found a fused fuse. :D

Its in a white fuse holder next to the radiator reservior bottle.

I just hope the fan is still okay. :shock:


Yes Jaq i tested the fan by letting the motor idle till it was over half way on the guage.

I changed the oil and oil filter. Cleaned the airfilter and applied airfilter oil. Tightened which felt like a million screws.

I'm gonna change the spark plug tomorrow. I couldn't find a plug spanner to undo the plug.
Title: KLR650 Restoration....Please help......
Post by: sidetrack on March 04, 2007, 04:26:00 pm
Check that the fans blades are not binding somewhere, I had a crash which caused my fans housing to catch on the fan. Run a fused 12v to the fan and check if it works.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 04, 2007, 07:58:18 pm
Nope the fan blades are not stuck.
I'm going to get some spare fuses tomorrow and when i assebled the bike again i'll test the fan. I'm sure the fan should still work.

Another question.

What kind of brake fluid should i put in the brake system?

Dot 4??
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 04, 2007, 08:05:54 pm
Upgrade the fuse under the seat to a 15A, think its 10A standard.
Ask oppad about this one quick of the KLR.

Brake fluid is DOT3 or DOT4
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2007, 07:17:56 am
Quote from: "shark_za"
Upgrade the fuse under the seat to a 15A, think its 10A standard.
Ask oppad about this one quick of the KLR.

Brake fluid is DOT3 or DOT4


Looks like the fuses is a commen problem with the KLR.
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 05, 2007, 07:44:29 am
Dude, there are 2....  
How hard can it get ;)
Title: KLR650 Restoration....Please help......
Post by: KiLRoy on March 05, 2007, 08:17:59 am
Quote
I have owned 8 KLR's. Six KL650C and two KL650A.


Are you a dealer?  A-model only officially imported from end of 2003? C-model (European model) was the only official KLR in SA prior to that.  Not nearly as much info and aftermarket advice/mods available as with the A-model (US model).

Safety features - mine acted up a few times - mostly when I don't want it to - like in hot places or in the rain.  Most RTW riders disable the safety features - period - check all the sources.  What I do like about the internet is even if these statements are made, adult people can still CHOOSE to do it or not - now thats a great idea - CHOICE.

What mods did you make to your A-models, and which would you recommend in doing ?

H
Title: KLR650 Restoration....Please help......
Post by: KiLRoy on March 05, 2007, 08:22:40 am
After I 'official' service with kawasaki, I'll trust the 'hobby mechs' any day before those assholes.  They got the valves wrong, didn't do the doohickey check and generaly forgot to tighten screws (like the steering nut) etc etc

I do most routine stuff myself, but for the more difficult stuff I've got a 'semi-prof' mech friend which I can trust and who's been working on bikes for more than 25 years. - very happy (he did the doohickey and valves)

H
Title: KLR650 Restoration....Please help......
Post by: Oppad on March 05, 2007, 09:56:43 am
Quote from: "shark_za"
Upgrade the fuse under the seat to a 15A, think its 10A standard.
Ask oppad about this one quirk of the KLR.


I know very little about 'lectrics but the general advice is to upgrade to 15A (not higher!) After blowing the main lights circuit fuse continuously I eventually took it to an auto-electrician who immediately diagnosed the cause as chafed wires rubbing against one another (even before he found the wires!) It all comes down to experience. In future I believe I'll find and fix the fault myself.

As far as the fan fuse is concerned I had mine blown recently. After it was replaced no problems as with the other fuse so I think it was just old age and nothing else. Le Cap (he really knows a lot) advises that the electric motor or thermostat switch will hardly ever give problems. He showed me how to quickly test for a working fan by pulling the wire from the thermostat switch (bottom left of radiator) and earthing it against the engine. No need for the bike to be switched on. If the fan goes on you have power getting through all the way.

If nothing is broken the fan will eventually come on, even if the gauge shows past the halway mark. Ride it for a bit trough traffic, park it and let it idle even if edges towards the top. The fan should come on within 3 minutes.

Cheers
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 05, 2007, 10:03:43 am
Quote from: "digitaldan"
Quote from: "lecap"

Guys who replace gaskets with GunGum and Hylomar.


Too expensive and messy, breakfast cereal boxes will also work  :twisted:


I always recommend Kellogs Corn Flakes packets myself.

Their cardboard seems to be of a better quality than other cereal food makers. :D
Title: KLR650 Restoration....Please help......
Post by: macduff on March 05, 2007, 10:45:03 am
strange,
i would have expected it to Snap, Crackle then Pop  :roll:  :roll:
Title: KLR650 Restoration....Please help......
Post by: lecap on March 05, 2007, 11:37:55 am
Quote from: "KiLRoy"
Quote
I have owned 8 KLR's. Six KL650C and two KL650A.


Are you a dealer?  A-model only officially imported from end of 2003? C-model (European model) was the only official KLR in SA prior to that.  Not nearly as much info and aftermarket advice/mods available as with the A-model (US model).

Safety features - mine acted up a few times - mostly when I don't want it to - like in hot places or in the rain.  Most RTW riders disable the safety features - period - check all the sources.  What I do like about the internet is even if these statements are made, adult people can still CHOOSE to do it or not - now thats a great idea - CHOICE.

What mods did you make to your A-models, and which would you recommend in doing ?

H


www.lecap.co.za (My website in urgent need of updates)

Not  a dealer. I run a tour operation. I am also busy setting up a small business importing and fitting aftermarket goodies to KLR's and DR's
I also fix and service other peoples KLR's and DR's and have all the wear & tear and easy to break stuff on the shelf. (incl. Eagle levers)

The C never needed that much aftermarket help as the A. It came with better front brakes and stronger forks as standard. The European suspension manufacturers Hyperpro, Wilbers and WP never bothered to make aftermarket fork springs for the KL650C as the originals worked fine.

Done on the A's and recommended:
Eagle lever
rear subframe bolts (if bike is used heavily loaded and / or on very rough terrain)
15A main fuse
SS allen bolts in handlebar switch units & throttle cable housing. The Japanese nails (Philips screws) don't want to come out any more after some time.
The same modifications were also done on my C's.

I am busy researching suspension upgrades for the A (= ordered parts for a test)
Progressive fork springs to reduce sag and diving on brakes
Shorter and harder rear shock spring to reduce spring preload for better suspension response.
Both modifications will also reduce bottoming out of the suspension riding the bike hard on rough terrain.

I am researching the price of upgrading the KL650A with a KL650C twin piston brake caliper (rotor is the same).

There is a lot of small things to do besides what I did if someone wants to make the KLR a better bike. Starting from getting R-clips for the axle nuts to replacing the brittle sofitten - type fuses with blade type fuses in an easily acessible place.

For those who like to play very rough I think a solid bashplate and some form of radiator protection (ideally the USMC tank  :D  ) should be on the wishlist. - I never had crash damages to the waterpump and no destroyed radiators a crash bar would have saved.

I found the "temperature gauge" on the "A" to be utterly useless. The "C" has a little lamp which comes on a while before you have steam blowing out of your radiator cap telling you there's something wrong. Sufficient.
I never managed to overheat a KLR with a working fan.
The fan test as described by Oppad should be routine. It only takes three seconds and the fan fuses often break from vibration.

The A's fuel tap is c**p effectively preventing you to drain some petrol for your buddy with the smaller tank. You also can't drain through the tap but have to syphon in the workshop.
The tap of the C model is much better having the positions On - Prime - Res and can be fitted to the A's tank. Also allows the bike to start immediately on Prime after having run dry.
Title: KLR650 Restoration....Please help......
Post by: IDR on March 05, 2007, 12:11:02 pm
Quote from: "lecap"

I am busy researching suspension upgrades for the A (= ordered parts for a test)
Progressive fork springs to reduce sag and diving on brakes

I am researching the price of upgrading the KL650A with a KL650C twin piston brake caliper (rotor is the same).


Would the caliper from the KLE fit??  Possibly even the fork, not that you'd want to do that though...
(http://img410.imageshack.us/img410/921/68155619xf9.jpg)
Title: KLR650 Restoration....Please help......
Post by: KiLRoy on March 05, 2007, 02:01:21 pm
Quote
I am busy researching suspension upgrades for the A (= ordered parts for a test)
Progressive fork springs to reduce sag and diving on brakes
Shorter and harder rear shock spring to reduce spring preload for better suspension response


One day i'll pop past your shop - i've done the Prog fork springs and fitted a stiffer rear spring - then you can check it out.

I've replaced most my bolts with ss allan keys too.  Use copper slip on front brake reservour.  Fitted a alu bashplate and HT res/rad protection etc etc

H
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2007, 02:23:51 pm
Le Cap. Keep up the good work. :D  Respect.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2007, 07:42:24 pm
Good news, replaced the fuse and the fan is working. Used Oppad's fan test.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2007, 07:47:14 pm
Finished the service on the bike.

Replaced oil, oil filter and spark plug.

Cleaned airfiler and applied airfilter oil.

Filled up front and rear brake fluid tanks. I overfilled the rear a bit. Hope it doesn't do any damage.  :shock:
I must say the brake fluid in the system doesn't look very good. :shock:

Fixed the indecator housing.

Bike is running nicely. :D  Quite proud of myself. I must say maintenance on the KLR is quite easy and i could almost call it fun.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2007, 07:54:45 pm
I found a willing mechanic to repair the broken spoke on my rear wheel. He will also straighten the wheel for me. :D

Now only to get the bleddie spoke from the stealer.  :x  Now thats another story.
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 06, 2007, 04:18:48 am
Quote from: "Captain Slow"
Finished the service on the bike.

Replaced oil, oil filter and spark plug.

Cleaned airfiler and applied airfilter oil.

Filled up front and rear brake fluid tanks. I overfilled the rear a bit. Hope it doesn't do any damage.  :shock:
I must say the brake fluid in the system doesn't look very good. :shock:

Fixed the indecator housing.

Bike is running nicely. :D  Quite proud of myself. I must say maintenance on the KLR is quite easy and i could almost call it fun.


If you've put too much in, simply get a clean rag, dip it in the fliud, the fluid will be absorbed into the rag.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 07:15:48 am
Quote from: "Jaqhama"
Quote from: "Captain Slow"
Finished the service on the bike.

Replaced oil, oil filter and spark plug.

Cleaned airfiler and applied airfilter oil.

Filled up front and rear brake fluid tanks. I overfilled the rear a bit. Hope it doesn't do any damage.  :shock:
I must say the brake fluid in the system doesn't look very good. :shock:

Fixed the indecator housing.

Bike is running nicely. :D  Quite proud of myself. I must say maintenance on the KLR is quite easy and i could almost call it fun.


If you've put too much in, simply get a clean rag, dip it in the fliud, the fluid will be absorbed into the rag.


Thanks for the advice Jaq. I'll go do that this afternoon. I must say the brakefluid currently in the system really doesn't look good. I looks like sour milk, with the pieces floating in it.  :shock:
Title: KLR650 Restoration....Please help......
Post by: IDR on March 06, 2007, 07:17:20 am
Quote from: "Captain Slow"
Quote from: "Jaqhama"
Quote from: "Captain Slow"
Finished the service on the bike.

Replaced oil, oil filter and spark plug.

Cleaned airfiler and applied airfilter oil.

Filled up front and rear brake fluid tanks. I overfilled the rear a bit. Hope it doesn't do any damage.  :shock:
I must say the brake fluid in the system doesn't look very good. :shock:

Fixed the indecator housing.

Bike is running nicely. :D  Quite proud of myself. I must say maintenance on the KLR is quite easy and i could almost call it fun.


If you've put too much in, simply get a clean rag, dip it in the fliud, the fluid will be absorbed into the rag.


Thanks for the advice Jaq. I'll go do that this afternoon. I must say the brakefluid currently in the system really doesn't look good. I looks like sour milk, with the pieces floating in it.  :shock:


You're going to have to replace that, BEFORE YOU RIDE IT!
Title: KLR650 Restoration....Please help......
Post by: lecap on March 06, 2007, 08:01:25 am
Quote from: "Captain Slow"

Thanks for the advice Jaq. I'll go do that this afternoon. I must say the brakefluid currently in the system really doesn't look good. I looks like sour milk, with the pieces floating in it.  :shock:


Nice, good brake fluid should be anywhere between clear (new) to yellow.
Brake fluid looking like strong tea (brown): It's old, replace it.

Sour milk with pieces floating in it  :shock:  :shock:  :shock:
Are you sure it's brake fluid?
I've seen stuff like that in 20 year old bikes. The concept of the KLR being that age is no excuse  :D
You should get all that stuff out and then pump fresh brake fluid through the system until it's clean.

Make sure the diaphagms covering the fluid reservoirs are fitted properly and are not damaged.

BTW: You do NOT have to top up your brake fluid reservoirs as long as you did not work on the hydraulic system of the brakes.
The reservoir is designed to feed brake fluid to the pistons as your pad linings wear. You change brake fluid and top up when you fit new pads. As they wear your fluid level in the reservoir will slowly drop towards the min. mark.
As soon as you fit new pads it will be back to max. and you won't have fluid squirting out of the top of the reservoir when you reset the brake caliper piston(s)  :)
The fluid level will now also give you a rough (!) indication about the wear condition of your pads.

Don't run the bike with an overfilled reservoir. When you fit the diaphagm and lid you might put some pressure onto the system eating up the play petween pads and rotor. This will harden up your pads at the least and can cause your brake to overheat and fail at the worst.
An overfilled reservoir will also make it very difficult to get the wheel out and in again as you are not able to push the pistons into the caliper.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 08:18:32 am
Thanks for the info guys. Will definitely take some of the brake fluid out.

Actually i think i should replace all the brake fluid like Le Cap said.

Le Cap do you know where i could buy a manual for the bike?

I looked all over the place. Can't find one. Can only download one from the net but how good is it. The cost is R110.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 06, 2007, 08:34:11 am
Quote from: "InsiderDirtRider"
Quote from: "lecap"

I am researching the price of upgrading the KL650A with a KL650C twin piston brake caliper (rotor is the same).


Would the caliper from the KLE fit??  Possibly even the fork, not that you'd want to do that though...


The KLE's caliper is slightly different (the KL650C's Tokico caliper does not have the differential pistons to even out pad wear). I have not tried it but I think the KLE's caliper will fit just like many others from other Kawasakis.
You will just have to be careful with master cylinder & caliper piston diametres.

The KL650C fork fits into the KL650A from its basic measurements. I am not sure to what extent the C's upper triple clamp will accomodate the A's instrument cluster.
The KLE's fork looks very similar to the KL650C's but you will have to check for overall length, length and diametres of steering head and suspension travel.
Aftermarket fork springs are definitely the more economic solution.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 11:08:42 am
Le Cap i see you also mention the 15A main fuse upgrade.

Isn't this a risky mod?

What happens when the fuse blows? I suppose you going nowhere. :shock:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 11:11:19 am
I think the neck or stearing bearings on my bike needs adjustment or replacement.

Any tips?

I guess till i have my manual i aint gonna do much to these bearings.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 12:45:49 pm
Jeezz this KLR650.net website has lots of info.

Looks likes lots of the guys have problems with the steering stem beerings and they adjust them. I think i should adjust mine. :D
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 06, 2007, 02:13:09 pm
Quote from: "Captain Slow"
Jeezz this KLR650.net website has lots of info.

Looks likes lots of the guys have problems with the steering stem beerings and they adjust them. I think i should adjust mine. :D


By the time you're finished you'll be able to tell all of us about how to replace/repair pieces of KLR 650. :D

I can see it now www.klrhintsandtips.co.za :lol:  :lol:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 02:21:39 pm
Quote from: "Jaqhama"
Quote from: "Captain Slow"
Jeezz this KLR650.net website has lots of info.

Looks likes lots of the guys have problems with the steering stem beerings and they adjust them. I think i should adjust mine. :D


By the time you're finished you'll be able to tell all of us about how to replace/repair pieces of KLR 650. :D

I can see it now www.klrhintsandtips.co.za :lol:  :lol:


Yes Jaq. I'm hungry for knowledge. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 07:14:35 pm
Removed the excess brake fluid but i really think i should drain that fluid. I'm gonna say this for the third time. Hell it doesn't look nice. I'm just waiting for my manual.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 07:16:51 pm
I checked the shock air pressure.

0.8 Bar each side. Is this correct?
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 06, 2007, 07:18:47 pm
Raise the front wheel off the ground so that there is no load on the forks. press the valves to equalise pressure.
Done.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2007, 09:52:49 pm
Quote from: "shark_za"
Raise the front wheel off the ground so that there is no load on the forks. press the valves to equalise pressure.
Done.


O thanks. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 07, 2007, 07:06:03 am
Does any have a rear wheel spoke for the KLR?

I know you get two types, the longer and the shorter one. I'm looking for the longer one.

I'm getting irretated with the stealer's nonsense. Parts never seem to arrive.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 07, 2007, 08:51:46 am
Quote from: "Captain Slow"
Le Cap i see you also mention the 15A main fuse upgrade.

Isn't this a risky mod?

What happens when the fuse blows? I suppose you going nowhere. :shock:


The 15A fuse does no harm. Under normal conditions it does not change a thing and if you have a short it will exceed 15A and blow the fuse.
The 10A tends to go when indicator globes or taillight globes go and sometimes just when switching high beam (the selector switch allows both high and low beam filament to be on when flicking it over rather than none)

Your KLR has two fuses under the seat and without looking it up in the manual I would say one supplies the ignition and starter solenoid whilst the other (the one that blows) supplies the lights. Means the blown fuse will only leave you in the dark. I use 15A fuses everywhere as this allows to substitute any of the two spares (one in the rubber mounting of the fuse box under the seat and one inside the fuse box of the fan) whereever it's needed.
Just make sure that you replace the spares as soon as possible.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 07, 2007, 09:04:02 am
Yes i bought a whole bag of fuses. At R0.5 a pop its no train smash. :D

The stealer just let me know my parts arrived. :D  I hope they are not lying. :shock:

I am still looking for a rear rim spoke. Thats all i still need.

I must say i read that whole KLR650 Faq website last night and its very informative. :D
Title: KLR650 Restoration....Please help......
Post by: lecap on March 07, 2007, 10:00:58 am
Quote from: "Captain Slow"
I think the neck or stearing bearings on my bike needs adjustment or replacement.

Any tips?

I guess till i have my manual i aint gonna do much to these bearings.


Replacing the bearings requires special tools. Even with the manual you will still need access to a well equipped mechanics shop to do it.

The first thing to check is for play:
Put a big box under the bike and have a big oke sitting on it to keep the front up and pevent the bike from moving.
Grab both sides of the fork at the bottom and pull forward. If you feel play the bearing is too lose. Don't get fooled by the play between inner and outer fork tubes.

Then you adjust:
I prefer to take the front wheel out. Gives yu a lot more feeling and we are talking precision here.
You loosen the bearing until you have play. Then you tighten it bit by bit until you reach the point where the play disappears. Note that the clampings of the fork tubes on the upper triple clamp have to be open and that you have to tighten the counternut on top of the triple clamp to check for the correct adjustment.

Once your steering head is adjusted you need to check for wear:
Turn the steering from side to side. It should move smoothly and not "lock" in certain positions.
If you want to check without taking anything apart go to a tire place that does wheel alignment.
Borrow one of the turntables which they put under the front wheels of the cars. Put your bikes front wheel onto it and turn the steering as above.

Lifting the front wheel off the ground and turning the steering often will not reveal a buggered steering head bearing.

Re: spokes: Unfortunately I can't help you with spokes. The KLR's wheels are quite tough and I never had to replace a single spoke.
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 07, 2007, 10:12:08 am
Re the spokes...no wreckers around?

No one who re-builds wheels?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 07, 2007, 10:55:45 am
Quote from: "Jaqhama"
Re the spokes...no wreckers around?

No one who re-builds wheels?


Found a guy that can fix the wheel for me. But he doesn't have a spoke. He said i should get them from the dealer.

I will go order one this afternoon.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 07, 2007, 11:01:33 am
I'm going to hopefully replace the front tyre with a new one on Saturday.

Should i replace the tube too, if i replace the tyre.
Title: Replace tube?
Post by: lecap on March 08, 2007, 08:19:33 am
Replace a tube if it shows any of the following defects:

Tube was losing pressure. A good tube should not drop noticably over a week or ten days. If you have to top up every second day get a new one.
I once ended up with a badge of Kings tubes which were porous from day one  :cry:  Used Bridgestones ever since.

Tube has folds.

Valve assembly is badly corroded where it sits in the tube.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 08, 2007, 10:49:53 am
I recieved my part yesterday.  :D

Front disk
Front pads
Front and rear sprocket
DID o ring chain
Fork seals

All for R2100 incl vat. Thats not bad at all.

I paid R590 for a front Michelin Anakee too.

If i can do most of the work myself i saved so much money that i can go and buy me that pair of nice soft panniers i have my eye on.  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 08, 2007, 10:54:41 am
Le Cap i'll do my Eagle lever conversion after my trip in April. There is no time for that at the moment.

The KLR FAQ website said you can hear when you've got a broken Doohickey.

They said you have to listen at the lower left side of the engine for abnormal noise. My engine is quite on the left side. I think.  :shock:

Is there a way to hear if the Doohickey is screwed?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 09, 2007, 07:09:13 am
I have to do that stem bearing tightening tonight. It kark going over the speed bumps and to use the front brake. Mine is really loose. :shock:
Title: KLR650 Restoration....Please help......
Post by: lecap on March 09, 2007, 09:18:41 am
Quote from: "Captain Slow"
Le Cap i'll do my Eagle lever conversion after my trip in April. There is no time for that at the moment.

The KLR FAQ website said you can hear when you've got a broken Doohickey.

They said you have to listen at the lower left side of the engine for abnormal noise. My engine is quite on the left side. I think.  :shock:

Is there a way to hear if the Doohickey is screwed?


When your doohickey is gone you will have a bit of slack in the balancer chain. It's very easy to make out the noise if you know what a healthy KLR should sound like  :?
With the engine idling you give the throttle a whack and as the engine responds you can hear a loud knock or two when the chain's slack is taken up and it slams into the guides.
If you know what to listen for it's actually very easy to separate the noise from the rest of the mechanical cacophony a healthy KLR engine produces  :D
You can also try using an old screwdriver:
Take the rubber plug cover (If you still have one) off the dohickey clamping screw underneath your alternator.
Start the engine, put the screwdrivers blade onto the head of the clamping screw and press the screwdrivers handle firmly against your ear.
Still very helpful if you know what your engine should sound like :D
Title: KLR650 Restoration....Please help......
Post by: lecap on March 09, 2007, 09:22:40 am
Quote from: "Jaqhama"
Re the spokes...no wreckers around?

No one who re-builds wheels?


I can give you a spoke but I have to take it out of a complete spare wheel = you have to give me the one you ordered or return mine when you change your next rear tire.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 09, 2007, 09:41:24 am
Quote from: "lecap"
Quote from: "Jaqhama"
Re the spokes...no wreckers around?

No one who re-builds wheels?


I can give you a spoke but I have to take it out of a complete spare wheel = you have to give me the one you ordered or return mine when you change your next rear tire.


No problem. Don't worry about the spoke already ordered 4 for myself. Should be here next week. :D

Thanks for the offer.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 09, 2007, 09:51:51 am
It makes sense. Hmm now to find a healthy motor.

My motor sounds alot like a John Deere tractor.  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 09, 2007, 07:53:50 pm
Working on the KLR is easy peasy. Its almost fun.

Tonight i set the stem bearings with the help of my newly acquired Clymer manual. Easy. :D

I bought my Loctite today. R46 for 6ml bleddie expensive. :shock:

I removed the front wheel too replace the tyre tomorrow.

While the wheel was off i replaced the front disk and also installed some new pads.

The Anakee is coming on tomorrow. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 09, 2007, 07:59:12 pm
I noticed another problem showing its ugly head.

As i was trying out my KLR in 50km/h PE winds to see how it would handle the wind. I must say it handles wind way better than my GSXR. Almost relaxing.

So back to the point i was going nicely in this hell of a head wind and i wanted to pass a car. I was in 5th gear probably 90km/h and i opened the throttle wide to let the lovely torque do its job when i noticed i'm going nowhere. Clutch is slipping.  :shock:

What could be the problem? Any tips and tricks?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 09, 2007, 10:04:20 pm
According to the manual the clutch slip could be one of three things.

1. Thin friction plates
2. Warped clutch plates
3. Weak springs

Another one is a incorrectly adjusted clutch cable. Mine is set correctly so i'll ignore that one.

Any ideas of the cost of these units?

I'll go find out tomorrow. :(
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 10, 2007, 04:09:14 pm
Got a price from the dealer for the clutch items.

Gasket, Friction plates, clutch plates, and springs. R950 incl vat.

The dealer told me that i only need a gasket, springs and friction plates.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 10, 2007, 04:51:07 pm
KLR hanging from the roof. Don't laugh at my garage/workshop. :D

(http://w2.bikepics.com/pics/2007/03/10/bikepics-824966-full.jpg)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 10, 2007, 04:53:18 pm
Many uses for a paint tin. :D

(http://w2.bikepics.com/pics/2007/03/10/bikepics-824968-full.jpg)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 10, 2007, 04:54:51 pm
Changing da brake pads.

(http://w2.bikepics.com/pics/2007/03/10/bikepics-824967-full.jpg)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 10, 2007, 04:56:40 pm
Brand new Michelin Anakee and new disk. :D

(http://w2.bikepics.com/pics/2007/03/10/bikepics-824971-full.jpg)
Title: KLR650 Restoration....Please help......
Post by: buzzlightyear on March 10, 2007, 05:44:00 pm
Always nice to see someone do the work themselves. I find inspiration in that, even though I probably have more than 2 thumbs.
Title: KLR650 Restoration....Please help......
Post by: Kaboef on March 10, 2007, 06:19:46 pm
Quote from: "nicki"
Always nice to see someone do the work themselves.


Especially if I can sit and drink beer while watching them.
 :D  :D
Title: KLR650 Restoration....Please help......
Post by: sidetrack on March 10, 2007, 06:58:46 pm
Quote from: "Captain Slow"
KLR hanging from the roof. Don't laugh at my garage/workshop. :D

(http://w2.bikepics.com/pics/2007/03/10/bikepics-824966-full.jpg)


Hey Captain I see you are an avid Superbike reader  :D
Title: KLR650 Restoration....Please help......
Post by: lecap on March 12, 2007, 08:12:44 am
Assuming that your clutch cable is adjusted correctly and moving freely:

Measure the clutch springs. If they are in spec don't replace!

The friction discs don't necessarily have to be worn down (too thin). Overheating them does the job as well (they get hard like overheated brake pads), is more likely on a low(ish) mileage DS bike and will be difficult to diagnose.
Warped steel discs come frequently together with overheated friction discs.
They will kill new friction discs quickly means check them carefully.
Title: KLR650 Restoration....Please help......
Post by: Grootseun on March 12, 2007, 08:19:06 am
Great workshop..nekkid chicks on the wall..perfect inspiration for tinkering with one's bike.

Wheredid you fit the radio on the KLR...dont you think the cd will bounce with all the KLR's vibes???

(http://w2.bikepics.com/pics/2007/03/10/bikepics-824967-full.jpg)


 :D  :D
Title: KLR650 Restoration....Please help......
Post by: IDR on March 12, 2007, 08:20:13 am
Captain Slow...this bike of yours has got my interest a little piqued... DNA motorcycles sticker on the swingarm, SBS (Scandinavian Brake Systems, KMSA-imported product) sticker on the fork, EC number plate.  Do you know what the history of the bike is?  I suspect that the clutch might be buggered because it was a demo...
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 12, 2007, 09:26:49 am
Quote from: "InsiderDirtRider"
Captain Slow...this bike of yours has got my interest a little piqued... DNA motorcycles sticker on the swingarm, SBS (Scandinavian Brake Systems, KMSA-imported product) sticker on the fork, EC number plate.  Do you know what the history of the bike is?  I suspect that the clutch might be buggered because it was a demo...


All i know it came from GP. It had GP numberplates.

The SBS pads i installed on friday afternoon and sticked the sticker to the fork.

DNA motorcycles. I've got no clue.

Remember the bike did 43 000km in two years. I think a new clutch can be justified.
Title: KLR650 Restoration....Please help......
Post by: Grootseun on March 12, 2007, 09:32:56 am
DNA Motorcycles is in Constantia kloof, near to where i reside. Had a look at some bikes there before i got my BM.

I think they are grey importers, but im not sure. Dont think they are suspect, they have been around for a couple of years now.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 12, 2007, 09:51:29 am
I must comment that there is a huge improvement in the braking of the KLR after setting the stem bearings, fitting new disk and pads and fitting the Michelin Anakee.

The Michelin has superb grip in the twisties on tar. :D  Quite entertaining.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 13, 2007, 07:11:32 pm
So i am investigating this clutch slip problem on my KLR.

The manual says: Excessive oil in the crank-case will make the clutch slip. Guess what the clutch started slipping right after i changed the oil. :shock:  So i checked the bike oil level and fooken hell it is overfilled. :shock:  The oil lies above the sight glass when the bike is upright. This is a nasty habbit that i can't seem to get rid off. Overfilling engines with oil.

So the plan is to wake up at 05:00 tomorrow morning and drain some of the oil. Then ride the bike to work and see if the clutch still slips. :D

Hold thumbs please. I'm not in the mood to replace a clutch.
Title: KLR650 Restoration....Please help......
Post by: KiLRoy on March 14, 2007, 02:57:01 am
It will take 2,5l of oil if the filter is replaced too.  The level will then be slightly above the sight glass.

H
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 07:10:33 am
Drained some of the oil.

Oil lying in middle of sight glass.

Clutch still slipping. :cry:

Dealer, stealer here i come. I'll open the clutch up thuesday or wednesday and check the status. But i don't know if the parts will arrive in time for me to fix the clutch before i go on the Trail rider trip.

I wonder if i should fiddle with the clutch right now before the trip.

It only slips when full throttle in 4th and 5th at around 5000 Rpm and higher. What do you guys think? :?:
Title: KLR650 Restoration....Please help......
Post by: lecap on March 14, 2007, 07:27:33 am
Quote from: "Captain Slow"
...
The manual says: Excessive oil in the crank-case will make the clutch slip
...


 :shock:  :shock:  :shock:

What manual is that??? Does it come with Mickey Mouse or naked girls on the cover???  :D

This statement, sorry, is complete bullshit. The clutch is running in the engine oil and it does not make a f***ing difference to the clutch if your oil level is a bit too high (whilst it can cause a number of other problems).

BTW: I do have friction discs in stock. Will look up the free length of the springs for you later at the shop (but I don't think they are causing your problem)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 08:05:10 am
Quote from: "lecap"
Quote from: "Captain Slow"
...
The manual says: Excessive oil in the crank-case will make the clutch slip
...


 :shock:  :shock:  :shock:

What manual is that??? Does it come with Mickey Mouse or naked girls on the cover???  :D

This statement, sorry, is complete bullshit. The clutch is running in the engine oil and it does not make a f***ing difference to the clutch if your oil level is a bit too high (whilst it can cause a number of other problems).

BTW: I do have friction discs in stock. Will look up the free length of the springs for you later at the shop (but I don't think they are causing your problem)


Clymer manual. In the troubleshooting section. :D

What do you think could be the problem Le Cap?

Have you had problems with KLR clutches before?
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 14, 2007, 09:22:52 am
Ah...having just caught up with the clutch slip problem old son....you didn't use an oil that had a cleansing agent in it did you?

Some oils (not bike oils) have an added substance which supposedly makes bike clutches slip.

Shell Ultra Helix is OK.
Mobil One is OK.
Most of Penzoil is OK.

All specific 4 stroke motorcycle oils are ok.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 09:28:40 am
Quote from: "Jaqhama"
Ah...having just caught up with the clutch slip problem old son....you didn't use an oil that had a cleansing agent in it did you?

Some oils (not bike oils) have an added substance which supposedly makes bike clutches slip.

Shell Ultra Helix is OK.
Mobil One is OK.
Most of Penzoil is OK.

All specific 4 stroke motorcycle oils are ok.


Nope, normal Castrol 20W-50 High milage GTX oil. Been using it for years in my car. :D
Title: KLR650 Restoration....Please help......
Post by: IDR on March 14, 2007, 09:33:41 am
Quote from: "Grootseun"
DNA Motorcycles is in Constantia kloof, near to where i reside. Had a look at some bikes there before i got my BM.

I think they are grey importers, but im not sure. Dont think they are suspect, they have been around for a couple of years now.


Nope, not grey importers...in fact, most successful Kawasaki dealer in Gauteng if I'm not mistaken...
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 14, 2007, 11:13:09 am
What addatives does high mileage have in it?

I used basic GTX and have no hassles.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 11:18:54 am
Quote from: "shark_za"
What addatives does high mileage have in it?

I used basic GTX and have no hassles.


Don't know. Its supposed to be good stuff. :shock:  :oops:

I'll have look. Mabe i can find a data sheet.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 11:45:11 am
I found this on the BMW Motorad site.

Interesting...... :shock:

"Use only high detergent, premium quality motor oil certified to meet API Service Classification SF or SG (shown on container). The use of additives is unnecessary and will only increase operating expenses. Do not use oils with graphite or molybdenum additives as they may adversely affect clutch operation."

Also found this on the BMW site:

Are there any "real world" examples of long motorcycle engine life using automotive oils? There's a good one in the June 1996 issue of Sport Rider magazine in a report called the "100,000 mile Honda CBR900RR." The owner used conventional Castrol GTX oil, 10W40 in the winter, 20W50 in the summer. He changed it every 4,000 miles, changing the filter every OTHER oil change. No valve clearance adjustments were required after the initial one at 16,000 miles. And a dyno test against the same model with only 6,722 miles showed torque and horsepower virtually identical. The 100,000 mile bike was even used for some racing. In a subsequent followup, the same CBR had passed 200,000 miles and was still going strong!

Clearly they are talking about the normal GTX. Not GTX high milage.

The high milage data sheet says it contains additives, but does not list them. :shock:

What do you guys think should i put some normal GTX in the motor and try it out. :?:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 11:50:23 am
The BMW site says that all these oils are good for use in motorcycles:

Castrol GTX 10w40; 20w50
Chevron Supreme 10w40; 20w50
Exxon Superflo 10w40;20w50
Mobil 10w40; 20w50
Pennzoil 10w40; 20w50
Quaker State 10w40; 20w50
Texaco Havoline 10w40, 20w50
Valvoline 10w40; 20w50
Valvoline VR1 Racing 20w50

They mention normal GTX but no High Milage.

Could this be the answer??
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 14, 2007, 03:12:48 pm
Quote from: "Captain Slow"
The BMW site says that all these oils are good for use in motorcycles:

Castrol GTX 10w40; 20w50
Used it...seems OK.
Chevron Supreme 10w40; 20w50
Don't have it here.
Exxon Superflo 10w40;20w50
Don't have it here.
Mobil 10w40; 20w50
Seems OK.
Pennzoil 10w40; 20w50
Used it, seems OK.
Quaker State 10w40; 20w50
Don't have it here.
Texaco Havoline 10w40, 20w50
Don't have it here.
Valvoline 10w40; 20w50
Valvoline VR1 Racing 20w50
I once read that Valvoline used to use a cleansing additive, so I've never used it.

They mention normal GTX but no High Milage.
Never used high Milage.

Could this be the answer??


I suspect this could be the problem.

You need to drain the oil, change to the regular GTX...go for a ride and see if the clutch slip has faded somewhat.
If yes, but is still there a bit...drain oil and repeat all.
If after another ride clutch is a little better, but still slips a tad...you could drain and repeat again, or you could remove, degrease/clean/wipe and reinstall clutch plates.
Bloody hell at this rate you'll have rebuilt the bike before I arrive.

I know this is stating the obvious but you have not run out of adjustment on your clutch cable have you?

Engines...car engines have a gearbox/clutch that is seperate to the engine. You put car oil in your engine but 80/90 gearbox oil in the gearbox/clutch and the shaft drive.
As I do with my old BMW bike, beacuse on the shaft drive Boxers the gearbox is seperate from the engine also.

In Japanese bikes the gearbox/clutch is part of the engine and so takes the same oil as the engine does.
Title: KLR650 Restoration....Please help......
Post by: Jaqhama on March 14, 2007, 03:26:16 pm
We've all got opinions here about the best oil to use in single cylinder bike engines.
There is a thread about it somewhere on this site.

I use normal car mineral oil in my old BMW bike.

But I only ever use a fully synthetic oil in my single cylinder late model trail bikes and the same in Terri's Ducati 600 Monster and Lin's ZZR 250.

I always use Shell Ultra Helix fully synthetic...and it ain't cheap.
Supposedly what Team Ferrari Italia uses in their race Ferrari's.

I will say that I've not had an engine wear problem in any bike I've used it in.

Now people say you can leave the oil changes longer when you use Syn Oil...that's not actually true...the oil still gets dirty...it's just the molecular structure is the same throughout the oil and so takes longer to break down than a mineral oil...that's the big diff between syn and mineral oil.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 03:30:11 pm
By the time you arrive in SA i'm a KLR pro.  :D

I'll put in some normal GTX this afternoon.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 14, 2007, 07:32:28 pm
Changed the oil to GTX. I think it feels better. Will see. Hold thumbs. :D
Title: KLR650 Restoration....Please help......
Post by: sidetrack on March 14, 2007, 07:59:42 pm
Which brings us back to  the point of not using car oils with additives in them for bikes ! Better yet stick to mc oils even if they are more expensive.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 15, 2007, 07:12:41 am
I'm sure it feels better. Clutch only slips a little at really high revs. I am able to maintain and excelarate to 140 without clutch slip. :D
Title: oil
Post by: bobnob on March 15, 2007, 07:27:03 am
Quote from: "digitaldan"
Which brings us back to  the point of not using car oils with additives in them for bikes ! Better yet stick to mc oils even if they are more expensive.


hi dd

how often do you change the oil in your drz?

bob
Title: KLR650 Restoration....Please help......
Post by: lecap on March 15, 2007, 09:33:52 am
Quote from: "Captain Slow"
...
Interesting...... :shock:

"Use only high detergent, premium quality motor oil certified to meet API Service Classification SF or SG (shown on container). The use of additives is unnecessary and will only increase operating expenses. Do not use oils with graphite or molybdenum additives as they may adversely affect clutch operation."
...



Gets it perfectly right. Although I am not sure about Molybdenium Disulfide see below.

I always use Caltex Delo Gold 15W40 on my KLR's
It's API SJ (higher API classification than SF or SG, the highest I ever saw on a non synthetic engine oil)
Caltex Delo Gold is a so called fleet oil. High quality. Good for about any four stroke automotive engine including turbocharged diesels (your bakkie :D ).
If it was ok for my Defender TDi's Turbocharger at 80000/min it should work for a KLR at 8000/min?
And it's cheap too.
Use Total Quartz synthetic on the oil cooled DR's. The oil temperatures tend to be higher than on the watercooled KLR's.

Specific bike oils:
When Shell started selling Quattro TX in the early eighties they claimed the oil to have "increased shear stability" (which it might have?) to protect your bikes gearbox. In your first year of studying engineering you will learn of evolvent gears (the ones in your gearbox): They roll on each other. Nothing shears :shock:
In the dark ages of OHV car engines the camshafts were often driven by gears. Same as distributors, oil pump and sometimes diesel injection pump shafts. No special oils to cater for them :shock:  :?
A typical application requiring a shear stable lubricant are the contact surfaces of cam and rocker / lifter / bucket and on most engines the con rod small end journal. Nothing bike specific.

I would not worry about using 15W40 instead of 10W40. Even in Sutherland it does not go below -10├?┬░C and you won't go riding in those temperatures anyway :)

I doubt the statement about molybdenium additives. Molybdenium disulfide as spray or paste is commonly used on white metal journals (most multi cylinder main shafts) and hardened steel / aluminium alloy journals (most camshafts) and cam / rocker or bucket contact surfaces (hardened steel / hardened steel) on reassembly to provide lubrication until oil pressure is build up and oil is supplied everywhere on first start.

Synthetic oil and clutch:
A myth!

Fact:
For the last couple of decades various materials were used for wet clutches. Asbestos, later ceramic fibrous compounds and sintered metals sometimes with ceramic additives.
They are all chemically quite inert. A quality engine oil will not affect them at all.
Previously they made clutch linings from stuff like leather and cork. If used in a wet clutch they require very careful lubricant selection as they have to be compatible with the organic friction materials and not swell or disintegrate them.
Very interesting that vintage engines have problems with oil additives much nore than with the base oil. The additives like black sludge inhibiting detergents attack not only their clutch linings but also cork gaskets and possibly latex (=natural rubber) seals.
That's why vintage bikes still run on single grade oil (Harley honey :lol: ) which contains little or no additives although a modern multigrade synthetic oil would do a better job to the mechanics.

The statement: "You can't use synthetic oil on a wet clutch motorcycle" is outdated by some 40 or 50 years.

Another fact:
Synthetic oil does not reduce friction in your engine in general. (At least not more than marginally). It is thinner when cold reducing wear because of being supplied faster to where it's needed.
It's thicker when hot keeping the oil pressure higher, working to higher temperatures before lubrication breaks down.
It also allows higher oil temperatures before thermal breakdown sets in.
The high temperature properties of a synthetic oil often reduce the engine's oil consumption figures (assuming the engine is mechanically ok).

While a change of the type of oil used in your engine might affect clutch operation (most notably sticking plates when starting a cold engine) it will not ruin your clutch by making it slip nor will it fix a slipping clutch.

I have used various synthetic engine oils on hundreds of motorcycles over the last twelve years and did not have a single case of a slipping clutch caused by the oil.

NEVER use miracle additives like SLICK, NULON and the like. They only make Verimark & Glomail rich.
If teflon coating would be so easy my Platino non stick frying pan would not have been so friggin' expensive  :lol:
Title: KLR650 Restoration....Please help......
Post by: Watty on March 15, 2007, 11:51:51 am
Quote from: "lecap"

I always use Caltex Delo Gold 15W40 on my KLR's
It's API SJ (higher API classification than SF or SG, the highest I ever saw on a non synthetic engine oil)
Caltex Delo Gold is a so called fleet oil. High quality. Good for about any four stroke automotive engine including turbocharged diesels (your bakkie :D ).
If it was ok for my Defender TDi's Turbocharger at 80000/min it should work for a KLR at 8000/min?....

A1 on this suggestion Lecap :thumbleft:  However, may I be so bold and rather recommend Caltex Delo 400 as an alternative to Caltex Delo Gold.  Although a bit more expensive than Gold, it have certain additional specifications.  Some info:

The "Flagship" product in the Delo├?┬« range is Delo├?┬« 400 Multigrade. With advanced ISOSYN? Technology this product provides unsurpassed protection in diesel and petrol engines, beyond the requirements of the latest industry standards.  In fact, Delo├?┬« 400 produced twice the wear protection, with equivalent fuel economy, in field tests against a leading synthetic diesel engine oil.

Delo 400 was the first engine oil to meet the world's first global 4-stroke diesel engine oil performance specification, Global DHD-1, and the highest API specification, namely the CI-4 specification.  It has in fact all the API ratings that exists.  Delo 400 is considered of very high value under high temperatures (as in South Africa), as it will retain its lubricity unlike certain regular SAE 40 oils, also it leave way less deposits in the engine, thus preventing soot damage and extending engine life, extending oil service life and filter life, maintaining fuel economy and oil consumption control.

I am using this oil in my Jeep Cherokee CRD and have noticed improve performance. I would definitely use it in any bike without hesitation! The last time I bought some at the local Caltex SA?s lubricants depot (October 2006) I paid about R130 for six litres.  Unfortunately I do not know about the availability and prices at the other places one would expect to buy oils (filling stations, Midas, etc.).

For more info open it?s Product Data Sheet (PDS)  (https://www.cbest.chevron.com/generated/MSDS/PDS7683075.PDF)at Calex?s Lubricants site and Proof of Performance (http://www.chevronlubricants.com/worldwide/asiapacific/ap_lubricantsforbusiness/ap_caltex_productindex1/ap_proofperf/default1.asp#delo) sheet.
Title: Re: oil
Post by: sidetrack on March 15, 2007, 08:52:45 pm
Quote from: "bobnob"
Quote from: "digitaldan"
Which brings us back to  the point of not using car oils with additives in them for bikes ! Better yet stick to mc oils even if they are more expensive.


hi dd

how often do you change the oil in your drz?

bob
Every 2000 km's
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 15, 2007, 09:19:55 pm
Guys i almost wanna put my left nut on the line and say i think the clutch is getting better. :D

Maybe i'm dreaming but it feels like its handeling more power before it slips.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 16, 2007, 09:17:51 am
Are you sure it's not just the partially seized cable that works its way free again?

The clutch cable forms some kind of a U - bend where it runs through the two radiator hoses above the water pump. The sleeves love to rust and seize the cable there. The result is that you have play at the clutch lever but no play at the mechanism at the lower end of the cable (where it's needed).
Make sure that you have play there and that the cable moves smoothly in the sleevce.
Also get a cable oiler. Pull the cable out of the clutch lever and flush with Q20 every few weeks or even better after washing the bike.

If cable and adjustment are ok I am afraid the improvement of the clutch will not last for long. I would pull it apart and check what's going on rather than breaking down in the middle of nowhere.
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 16, 2007, 09:25:48 am
KLR clutch cable is R50 or so, get a new one, run it next to the current one secured with cable ties.
Tape up the ends with plastic and tape, one times instant spare available when it fails.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 16, 2007, 09:37:24 am
Quote from: "shark_za"
KLR clutch cable is R50 or so, get a new one, run it next to the current one secured with cable ties.
Tape up the ends with plastic and tape, one times instant spare available when it fails.


Cool. Is it R50 from the dealer.

I'm sure my cable adjustment is correct. The cable is slack.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 17, 2007, 11:52:23 am
Just a report.

Feels like clutch slip is getting better after i changed the oil.

Fuel econmy is really good. My first figures was 18.6 km/l.

At the moment i am at 400km on my current tank and i haven't hit the reserve yet. This tank inclueded a 180km run at 80km/h - 130km/h and the rest was town riding. I must say in town i'm not going slow at all. I'm really addicted to that lazy torque.

As far as i know the tank is 20l + 3l reserve.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 19, 2007, 04:57:12 pm
Was cleaning up my stores today. Have OEM KLR clutch steel plates, friction plates and springs in stock.  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 09:33:31 am
Quote from: "lecap"
Was cleaning up my stores today. Have OEM KLR clutch steel plates, friction plates and springs in stock.  :D


Good to know Le Cap. :D

What do you think Le Cap. Do you maybe have a gasket set lying around somewhere that i can take of your hands?  :D

I wanna have a peek inside at the clutch. Whats the chances that i can put the old gasket back when i close the cover. You see the problem is i can't open the cover because the stealer can't get me a gasket in time to close the cover again.

A guy also mentioned to me to sandpaper the clutch plates and friction plates, then rinse them in petrol. He also said i could put shim washers behind the spring to give em more power. If thats all i have to do then all i need is a gasket. :D  What do you think.

I must say i rode the KLR all day yesterday on dirt and on highways and the clutch slip only appeared at 140km/h, which to me is way to fast for a KLR anyway. :D

Then the shirt hit the fan. I had to lift a cherry around, it slipped easily in fith gear.  :shock:
Title: KLR650 Restoration....Please help......
Post by: Welsh on March 22, 2007, 10:01:31 am
Quote from: "Captain Slow"
Quote from: "lecap"
Was cleaning up my stores today. Have OEM KLR clutch steel plates, friction plates and springs in stock.  :D


Good to know Le Cap. :D

What do you think Le Cap. Do you maybe have a gasket set lying around somewhere that i can take of your hands?  :D

I wanna have a peek inside at the clutch. Whats the chances that i can put the old gasket back when i close the cover. You see the problem is i can't open the cover because the stealer can't get me a gasket in time to close the cover again.

A guy also mentioned to me to sandpaper the clutch plates and friction plates, then rinse them in petrol. He also said i could put shim washers behind the spring to give em more power. If thats all i have to do then all i need is a gasket. :D  What do you think.

I must say i rode the KLR all day yesterday on dirt and on highways and the clutch slip only appeared at 140km/h, which to me is way to fast for a KLR anyway. :D

Then the shirt hit the fan. I had to lift a cherry around, it slipped easily in fith gear.  :shock:


My advice,
1) No problem with sand papering the friction plates a little.
2) Do not put washers behind the springs, you will have a 80% chance that the clutch will drag if you do. Rather replace the friction plates.
3) check your plates on a sheet of plate glass to see if they are flat.

Welsh  8)
Title: KLR650 Restoration....Please help......
Post by: lecap on March 22, 2007, 10:51:11 am
Shimming the springs does not really help a lot as it does not make the springs harder, only gives them a little bit more preload.
If your springs are worn it means they have set. Decreasing the free length of a spring whilst keeping all other measurements constant decreases the spring rate.

I have all KLR gaskets in stock including cylinder foot, cylinder head and valve cover rubbers. Also waterpump shaft seals.
Also have 1st oversize pistons with rings, pins and clips.
A briefcase full of valve shims.
All cables.
Clutch & brake levers, stronger gearshifters, choke levers and all the other easy to break rubbish.

You can often reuse the paper gasket of the engine side covers. If the cover has been off before and the mechanic fitting the cover oiled the gasket before fitting it then it usually comes off in one piece.

I also have a set of aftermarket friction plates for the KLR flying around (Vesrah) Suspect it's the same as OEM just in another box. You can have them for 200 bucks.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 11:06:44 am
Gee thanks Le Cap. Check your PM. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 02:35:39 pm
Once again i just wanna thank Le Cap.

Guys and girls if you own a KLR Lep Cap is the oke to know. :D

He is sending me parts overnight for my KLR and i'm very happy. The dealer stealer takes about 2 weeks to loose the parts you ordered. :evil:

Thanks man.  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 02:38:41 pm
Just a report.

Tested the KLR's fuel economy again.

Reading attained is 21.6km/l. Blikslaer dis goed. :shock:  :D

Oil used in 500kms. None.  :D
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 22, 2007, 02:40:30 pm
You ride a lot slower than me.
Or something is broken on my bike.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 02:56:30 pm
Quote from: "shark_za"
You ride a lot slower than me.
Or something is broken on my bike.


No no. Not slow. Ride between 80 - 130 all the time.
Won't ride at 140. Wind resistance to much.

In town i'm like a hooligan.

The name Captain Slow is sarcasm. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 02:59:33 pm
On my first tank i got 18.6km/l.

But that was open throttle lots of times and in 40km/h PE winds.

Shark how much do you get?
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 22, 2007, 03:20:38 pm
17 or so.
Title: KLR650 Restoration....Please help......
Post by: JourneyMan on March 22, 2007, 03:28:08 pm
Quote from: "shark_za"
You ride a lot slower than me.
Or something is broken on my bike.


Maybe extra weight? :twisted:  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 03:28:51 pm
Quote from: "shark_za"
17 or so.


Do you have performance mods and zorst?

I'll report back after my trip to the western cape in April. Then we'll se how much fuel and oil my baby uses.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 22, 2007, 03:41:47 pm
Quote from: "JourneyMan"
Quote from: "shark_za"
You ride a lot slower than me.
Or something is broken on my bike.


Maybe extra weight? :twisted:  :D


Well i'm 115kg. Shark how much are you? :D
Title: KLR650 Restoration....Please help......
Post by: shark_za on March 22, 2007, 04:06:51 pm
Less than that, but not much!  109

Thanks JM !
Title: KLR650 Restoration....Please help......
Post by: IDR on March 22, 2007, 04:10:01 pm
Don't you okes want to go look in on the weight loss thread?  :twisted:
Title: KLR650 Restoration....Please help......
Post by: Welsh on March 22, 2007, 04:32:16 pm
Quote from: "Captain Slow"
Quote from: "shark_za"
17 or so.


Do you have performance mods and zorst?



He has a performance throttle cable, closed to wide open is very short.

Welsh  8)  8)
Title: KLR650 Restoration....Please help......
Post by: Welsh on March 22, 2007, 04:34:26 pm
Quote from: "InsiderDirtRider"
Don't you okes want to go look in on the weight loss thread?  :twisted:


No thanks, anyway anybody sub 130kg is a Kate Moss in my books!!!!!  :D  :D  :D  :D
Lunch today was Portugese Chicken at CESCO,S washed down with a couple of Pilsner Urquelle,s a couple of bottles of Sauvignon Blanc and an Irish. Don,t feel much like working now.

Welsh  :oops:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 23, 2007, 12:26:15 pm
Part arrived leaving work now. Gonna install the new friction plates. :D
Title: KLR650 Restoration....Please help......
Post by: IDR on March 23, 2007, 12:35:27 pm
Quote from: "African Welsh"

Lunch today was Portugese Chicken at CESCO,S washed down with a couple of Pilsner Urquelle,s a couple of bottles of Sauvignon Blanc and an Irish. Don,t feel much like working now.


Hmmm... Are you a Cesco's regular?  If you ever see an old toppie, looks a lot like me, just a very much older version...often there's two of them... Don't believe a word either of them say, it's all nonsense!  :D
Title: KLR650 Restoration....Please help......
Post by: Welsh on March 23, 2007, 01:35:02 pm
Quote from: "InsiderDirtRider"
Quote from: "African Welsh"

Lunch today was Portugese Chicken at CESCO,S washed down with a couple of Pilsner Urquelle,s a couple of bottles of Sauvignon Blanc and an Irish. Don,t feel much like working now.


Hmmm... Are you a Cesco's regular?  If you ever see an old toppie, looks a lot like me, just a very much older version...often there's two of them... Don't believe a word either of them say, it's all nonsense!  :D


This was Cesco,s in Kelvin, which one are you on about?

Welsh  8)  8)
Title: KLR650 Restoration....Please help......
Post by: IDR on March 23, 2007, 01:37:52 pm
Quote from: "African Welsh"
This was Cesco,s in Kelvin, which one are you on about?


same one.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 23, 2007, 04:04:07 pm
Removed the clutch plates and checked everything. Everything seems allright. Everything is in spec. No buckle in clutch plates. Friction plates still thick enough and springs still long enough. The friction plates look a bit glazed.

Will report back later.
Title: KLR650 Restoration....Please help......
Post by: Kaboef on March 23, 2007, 04:06:26 pm
Quote from: "Captain Slow"
Removed the clutch plates and checked everything. Everything seems allright. Everything is in spec. No buckle in clutch plates. Friction plates still thick enough and springs still long enough. The friction plates look a bit glazed.

Will report back later.


Hey man, dont hijack this thread!

 :D  :D  :D
Title: KLR650 Restoration....Please help......
Post by: lecap on March 23, 2007, 04:30:20 pm
Burnt friction plates is the usual problem. I have never seen plates worn beyond the limit in a wet multi plate clutch. Think the engines don't make it long enough. Some bike models tend to have problems with springs setting.

For the record: Your bike has the reinforced 38mm springs and the new clutch basket with the additional short groove? I never had the clutch cover off my A models.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 23, 2007, 10:17:52 pm
After lots of experimentation with different oils, etc. i decided to install new friction disks in the clutch.
Will go and test ride it tomorrow morning. Rode it around the block a few times and it feels like the clutch has more bite. But tomorrow on the highway will be the real test.

All the clutch components are still according to spec and should function correctly, but it kept on slipping at full power. Will see tomorrow. Hold thumbs.

O yes Le Cap motorcycles in Cape Town a great thanks to you for supplying me the parts overnight and at such a good price. Only R200 for a full set of friction plates. :notworthy:

(http://img407.imageshack.us/img407/7461/clutchnt4.jpg)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 24, 2007, 04:53:10 pm
I'm happy to report that the clutch doesn't slip anymore.

I was able to reach 160km/h on the clock this morning. Kept it at 150 for a few kays. No slip.

Third tank on the KLR, 21.1km/l. Jeezzz thats good.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 25, 2007, 09:25:36 am
The R 200 was NOT the official retail price. I had the set for ages and wanted to get rid of them. The price marked on the box was R 431 and that's probably from 1998?
Happy to hear that your clutch is fine again.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 25, 2007, 02:46:56 pm
Thanks again.

I saw the price on the box.

Did more than 200km on her today and the clutch is perfect. :D
Title: KLR650 Restoration....Please help......
Post by: lecap on March 26, 2007, 08:51:55 am
Quote from: "lecap"
For the record: Your bike has the reinforced 38mm springs and the new clutch basket with the additional short groove?


?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 28, 2007, 09:13:14 am
Looks like i will be going on my trip saturday with one spoke missing from the rear wheel. :shock:

The parts has been on order for a month now at the dealer and no luck. :evil:
Title: KLR650 Restoration....Please help......
Post by: lecap on March 28, 2007, 05:13:03 pm
The offer to borrow one is still valid.
You can send it back as soon as you get the new ones or send me a new one.
Postnet will also be cheaper than for the clutch. (Should have sent it with the same parcel but was sure you have the spoke already)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 28, 2007, 09:16:21 pm
Quote from: "lecap"
The offer to borrow one is still valid.
You can send it back as soon as you get the new ones or send me a new one.
Postnet will also be cheaper than for the clutch. (Should have sent it with the same parcel but was sure you have the spoke already)


Will i have to remove the wheel if i want to put in the spoke? The thread part on the rim side of the wheel is still intact.

Le Cap i've been riding the bike for 800km without the rear spoke and sometimes even with a pillion. I think i'll be okay. I'll replace it after the trip. Thanks for the offer.
Title: KLR650 Restoration....Please help......
Post by: lecap on March 29, 2007, 08:19:01 am
As long as you're careful not to push the nipple into the wheel you can just stick the new spoke in and tighten it.

You have to deflate the tyre completely though as the nipples love to cut through your rim tape and the tube if you turn them while the tyre is inflated.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 29, 2007, 10:01:46 am
Quote from: "lecap"
As long as you're careful not to push the nipple into the wheel you can just stick the new spoke in and tighten it.

You have to deflate the tyre completely though as the nipples love to cut through your rim tape and the tube if you turn them while the tyre is inflated.


Okay thanks Le Cap. I think you can send one over.

I need the longer one of the two spokes on the rear wheel.

Check your email.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on March 30, 2007, 02:55:48 pm
Thanks to Le Cap for organising me some KLR spokes overnight.

Going to install them tonight after work.

I wouldn't have felt very comfortable knowing one spoke was missing.
Title: KLR650 Restoration....Please help......
Post by: Welsh on March 30, 2007, 04:08:40 pm
Quote from: "Captain Slow"
Thanks to Le Cap for organising me some KLR spokes overnight.

Going to install them tonight after work.

I wouldn't have felt very comfortable knowing one spoke was missing.


Just do not overtighten them.

Welsh  8)  8)
Title: KLR650 Restoration....Please help......
Post by: D7 on April 05, 2007, 04:43:08 pm
Had a scarey event this am.   One of the bolts which secure the footpegs to the frame,  sheered.   Half the bolt was still stuck in the frame.   Patience, a hammer and screwdriver thankfully got it out fairly quivkly.   Went with the bosses car this pm to a place called 'JKM' cnr oxford and long in ferndale (randburg). R3-90 for 4 replacement bolts (12.9 strength with allan key tops) and some washers. R10-95 for an umergency set of allan keys from the hardware store at the rosebank mall.  

I recon it's a worthwhile upgrade.   If that bolt had sheered when I was standing up - as I often do in heavy trasffic for the better view - I would probably have totalled myself.   Bear in mind I only weigh in at 90kg.
Title: KLR650 Restoration....Please help......
Post by: lecap on April 05, 2007, 04:58:29 pm
IMHO they snap because keen mechanics overtighten them. I had one falling out on a KL650C a few years ago and never had problems again (used Loctite).
Don't recall the recommended torque but it's only an 8mm bolt and therefore lies well in the snap-by-biceps range.
Title: KLR650 Restoration....Please help......
Post by: Lootch67 on April 05, 2007, 06:22:20 pm
I lost a footpeg the first time I took the KLR for a proper off-road ride when the bolts vibrated loose. Scary as hell I tell you. Report here (http://wilddogtours.co.za/forum/viewtopic.php?t=2173&highlight=salisbury) Now properly secured with copious amounts of Loctite.
Title: KLR650 Restoration....Please help......
Post by: lecap on April 07, 2007, 08:54:12 am
The KL650C manual gives 29Nm.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on April 07, 2007, 06:58:51 pm
Spoke is fitted to KLR. Did my footpegs with loctite a while ago.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on April 22, 2007, 12:03:58 pm
Le Cap your spokes are on their way. Should reach you by about Thursday.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on April 22, 2007, 12:09:52 pm
The newest problem with my KLR is the following:

The radiator fan stays on all the time.

When i turn the ignition on - the fan goes on.
When i turn the ignition off - the fan goes off.

I pulled the fan switch connector from the switch to break the circuir - the fan keeps running.

I think the fan relay may be stuck.

I've been riding like this since the Klein karroo trip but its getting irretating now.

I'll strip the bike over the long weekend. I'll do a proper service and fix the fan. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on April 22, 2007, 12:14:41 pm
This may seem as a stupid question: Is there any adjustments that can be made to the rear suspension on the KLR.

My rear suspension is really soft. It sags by just looking at it. :lol:
Title: KLR650 Restoration....Please help......
Post by: Welsh on April 22, 2007, 04:03:52 pm
Quote from: "Captain Slow"
This may seem as a stupid question: Is there any adjustments that can be made to the rear suspension on the KLR.

My rear suspension is really soft. It sags by just looking at it. :lol:


Try raising links, shark used some, or lose weight.

Welsh  :D   :D
Title: KLR650 Restoration....Please help......
Post by: lecap on April 23, 2007, 07:42:55 am
You can set preload of the spring as well as rebound damping of the shock:
For preload you use a 12mm socket and turn the adjuster bolt on the top of the shock clockwise.
(Look towards the shock from the lhs of the bike. The 12mm hex sits on top of the spring just below the upper shock mounting and has a little circlip behind it)
Your preload will increase in four steps indicated by marks on the housing before it goes back to min. with a big bang.
You should crank the preload adjuster through a few times every time you service the bike as they tend to corrode to shit if not used over a long time.
For rebound damping adjustment you have to take a little black plastic cover off the bottom of the rear shock just above the connection to the suspension linkage. Behind the cover is a little adjustment wheel that sets the rebound damping in five positions.

As a rule of thumb the damping setting should be the same as the preload (i.e. preload =3; damping =3).

The OEM shock is fine for general use and IMHO works satisfactory even two up unless it's very old & worn.

Top quality aftermarket replacements range from approx. R 4000 to R 7000 depending on what you use the bike for (and more but the fully adjustable racing types don't really make sense on a KLR).
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on April 23, 2007, 08:50:12 am
Thanks Le Cap

Will set it this weekend.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on April 27, 2007, 01:14:12 pm
I set the KLR suspension this morning.

Was on setting one for preload and setting one for rebound damping.

Set both to the third setting. Eish what a difference. :D
Title: KLR650 Restoration....Please help......
Post by: Welsh on April 27, 2007, 03:02:51 pm
Quote from: "Captain Slow"
I set the KLR suspension this morning.

Was on setting one for preload and setting one for rebound damping.

Set both to the third setting. Eish what a difference. :D


So no Diet Required.

Welsh  8)  8)

Show me the man who has not tasted his own snot!
And I show you a liar
Title: KLR650 Restoration....Please help......
Post by: lecap on May 02, 2007, 08:02:05 am
Quote from: "Captain Slow"
I set the KLR suspension this morning.

Was on setting one for preload and setting one for rebound damping.

Set both to the third setting. Eish what a difference. :D


The rear suspension is up to things as long as it's one up and not too much luggage. They also last well.
The front needs help from word go. The fork springs are too soft.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 02, 2007, 08:36:58 pm
Jip those front springs are way to soft.

Will get some better springs from you later on Le Cap. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 02, 2007, 08:47:58 pm
It me again. :D

On the trailrider trip i broke some of the mounting brackets on those stupid looking right and left side covers that attaches to the tank.

Each cover has two mounting points with screws and a third point that just clips into a rubber stay.

I broke some of these brackets on both covers.

What would be the easiest way to repair this? Glue doesn't work. Allready tried Pratley epoxy. I was thinking of making little stainless steel L brackets and mounting them onto the plastic cover by drilling holes and fitting counter sunk alancap bolts. After that i can maybe put new stickers on.

Bringing me to another point how much will those KLR stickers cost me and do KMSA sell the stickers?  :D
Title: KLR650 Restoration....Please help......
Post by: lecap on May 02, 2007, 11:40:01 pm
Just ignore the broken plastic clip ins. The covers don't fit properly in any case and as long as the clip ins are in place they keep on popping out all the time. They are broken off or poped out on any KLR you see except stationary ones in the showroom.
The three bolt on mounting points hold the covers firmly in place. Why worry about the useles fourth one?

(BTW: My allen head bolts to bolt the covers onto the tank donot go AWOL like the original philips ones:-)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 03, 2007, 06:59:12 am
No no Le Cap.

The screw in ones broke off.

I'll take a pic later and post it. :D
Title: KLR650 Restoration....Please help......
Post by: Oppad on May 03, 2007, 10:19:00 am
Quote from: "Captain Slow"
It me again. :D

On the trailrider trip i broke some of the mounting brackets on those stupid looking right and left side covers that attaches to the tank.

Each cover has two mounting points with screws and a third point that just clips into a rubber stay.

I broke some of these brackets on both covers.

What would be the easiest way to repair this? Glue doesn't work. Allready tried Pratley epoxy. I was thinking of making little stainless steel L brackets and mounting them onto the plastic cover by drilling holes and fitting counter sunk alancap bolts. After that i can maybe put new stickers on.



same kind of thing happened here. First tried to fix it with epoxy (it lasts until the next off) and then just drilled little holes and fixed it sort of permanently with cable ties. That's the beauty of a KLR - a cable tie fix looks upmarket.
Title: KLR650 Restoration....Please help......
Post by: Welsh on May 03, 2007, 10:27:28 am
Quote from: "Oppad"
Quote from: "Captain Slow"
It me again. :D

On the trailrider trip i broke some of the mounting brackets on those stupid looking right and left side covers that attaches to the tank.

Each cover has two mounting points with screws and a third point that just clips into a rubber stay.

I broke some of these brackets on both covers.

What would be the easiest way to repair this? Glue doesn't work. Allready tried Pratley epoxy. I was thinking of making little stainless steel L brackets and mounting them onto the plastic cover by drilling holes and fitting counter sunk alancap bolts. After that i can maybe put new stickers on.



same kind of thing happened here. First tried to fix it with epoxy (it lasts until the next off) and then just drilled little holes and fixed it sort of permanently with cable ties. That's the beauty of a KLR - a cable tie fix looks upmarket.



 :D  :D  :D  Strue,

Welsh
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 03, 2007, 01:47:22 pm
Mine is getting polished stainless button head screws. Now thats gonna look upmarket.  :D

Currently busy with it.

Fixed the radiator grill while i'm at it and gave i a new coat of paint. Snazzy. Hehe :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 05, 2007, 12:59:23 pm
Le Cap i see what you mean with front springs being to soft on the KLR.

As you know i played with the settings on the rear shock absorber. Set it to 3 for preload and 3 for rebound damping. Took the bike for a 100km ride yesterday afternoon on a bumpy back road that i rode many times before. The handeling was horrible. The rear suspension was set to hard, will set it down to 2nd setting on both today.

With the rear suspesion set hard and the front being as soft as it is, i ran wide in lots of the corners. Under braking the front dips badly. This wasn't very evadent when the back was set soft.

I'm gonna soften the rear again.

How much are those springs? :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 08, 2007, 02:03:23 pm
The brackets are finally ready.

Brackets from 304 stainless and so are the screws.

Screws needs to be polished and the brackets fitted to the panals.

If i work according to Captain Slow speed it should be finished in a week or three. :D

(http://img406.imageshack.us/img406/2716/bracketer7.jpg)
Title: KLR650 Restoration....Please help......
Post by: Grootseun on May 08, 2007, 02:11:44 pm
hmmmm... more oak desks... :?  :?
Title: KLR650 Restoration....Please help......
Post by: lecap on May 09, 2007, 08:57:28 am
Get flanged buttonhead bolts in A2-70 and scrap the washers!
Polishing the bolts? Dude, it's not a Harley  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 09, 2007, 09:50:20 am
Quote from: "lecap"
Get flanged buttonhead bolts in A2-70 and scrap the washers!
Polishing the bolts? Dude, it's not a Harley  :D


Le Cap if i could find flange button heads i would use them. Can't find any. :oops:
Title: KLR650 Restoration....Please help......
Post by: lecap on May 09, 2007, 10:35:03 pm
I sell them in my KLR fastener kits and I also sell them loose  :D
Title: KLR650 Restoration....Please help......
Post by: D7 on May 10, 2007, 06:07:12 am
treat yourself and get the fastener kit.
it's a gift you'll never stop loving :)


being a klr,  you're going to be using those fasteners often :shock:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 10, 2007, 07:15:34 am
Quote from: "lecap"
I sell them in my KLR fastener kits and I also sell them loose  :D


Ai Le Cap, you are my hero.  :D
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 10, 2007, 07:57:31 am
You sell KLR fasteners loose?
So the KLR does not even have to shake them loose itself!

WOW!
Title: KLR650 Restoration....Please help......
Post by: lecap on May 10, 2007, 03:40:44 pm
Top service, eeeeh?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 13, 2007, 11:44:34 am
Yesterday was operation "Bleed the KLR brakes" day.

I bought some brake fluid. A buddy of mine came to assist me.

So we bled my KLR brakes with the help of the Clymer manual.

Wow what an improvement.  :D  Brakes have way more feel and are nice and hard. No more spongy feel.

Its quite a messy job. Luckily i didn't get any brake fluid on my paintwork.

The brake fluid that came out the KLR system was brown in colour. Not good. :shock:



So my buddy says since it made such an improvement on the KLR lets try it on his CBR.

Down we go to the shop. Buy another bottle.

Bled his brakes.... Made a huge improvement.

His brakefluid was black. :shock:  :shock:   :lol:

Never ever bled the brakes and the bike is over 10 years old. :lol:

Bleeding the brakes cost me R24 for the fluid. Cheap and easy if you are two people doing it.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 17, 2007, 07:09:23 am
I've got a new problem. I'm not sure if it is a problem.

I noticed the bike has been pushing a little bit of engine coolant out of the overflow pipe from under the numberplate.

I got a bit worried and looked in the expansion bottle. Bottle was filled up to above the full mark.

Then i checked the radiator for coolant and fark me to my surprise i cant see any water. So i filled it up at the radiator.

Rode alone for about a monthe or so. Noticed again this weekend that it is pushing coolant out of the overflow pipe back at the numberplate.

Again i checked the expansion bottle and jeeezzz it is almost filled right to the top, full full. Checked the radiator, can't see water.

It looks like the radiator moves some of its water over to the expansion bottle but it doesn't come back again.

Could the little pipe at the bottom of the expansion bottle be blocked?? Thats my only thought.

The bike is still safe, kept a close eye on the temperature guage. It never goes over halve.
Title: KLR650 Restoration....Please help......
Post by: lecap on May 17, 2007, 09:54:51 am
Looks like a vacuum leak:
The engine heats up - coolant expands and gets displaced into reservoir.
The engine cools down - coolant contracts but because of a vacuum leak it is not sucked back into the cooling circuit but replaced by air sucked in through the vacuum leak.
Most probable location for a vacuum leak is the radiator cap.
Give it a nice clean. If it does not get better get a replacement from Midas et al. Only a few Rand.
Note that a generally leaking radiator cap will do the same on a KLR:
As the coolant expands it will run into the reservoir bottle by gravity feed only without leaking from the radiator cap.

If cleaning / replacing the radiator cap does not help (very unlikely) get the coolant circuit pressure tested at a radiator place.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 17, 2007, 10:09:06 am
Le Cap thanks for the info.

The radiator cap makes a shhhhhtttt noise when i open it. So can it be leaking then? I'll clean it anyway.
Title: KLR650 Restoration....Please help......
Post by: sidetrack on May 17, 2007, 01:26:37 pm
Maybe the return pipe is kinked or blocked ?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 17, 2007, 01:52:01 pm
Quote from: "digitaldan"
Maybe the return pipe is kinked or blocked ?


I'll check it for kinks. I don't think its blocked anymore if it was, because i connected a pipe to the expansion bottle top and removed the radiator cap. Then i blew on the pipe with my mouth. The radiator filled up with coolant from the expansion bottle. Thats how it is supposed to work. :D

I'll keep an eye on it anyway. It looks like i had to much coolent in the system too. :shock:

I checked and cleaned the radiator cap, it looks fine to me. Also there are no visual leaks on the system.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 24, 2007, 09:02:04 am
I want to paint the KLR's exhaust so it looks all new again.

What kind of paint can i use??

The exhaust is currently black and a brown rusty color. Yukk..  :D
Title: KLR650 Restoration....Please help......
Post by: Welsh on May 24, 2007, 09:16:22 am
Quote from: "Captain Slow"
I want to paint the KLR's exhaust so it looks all new again.

What kind of paint can i use??

The exhaust is currently black and a brown rusty color. Yukk..  :D


I suggest you just go for the Black not the black and brown.

Most car places will stock heat resistant black, but make sure you clean all the old dusty rust off first. It does not generally last too long though.

Welsh  8)
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 24, 2007, 09:32:43 am
Powerflow !
Title: KLR650 Restoration....Please help......
Post by: Grootseun on May 24, 2007, 09:47:19 am
it comes in a nice chrome finish.. 8)
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 24, 2007, 09:53:01 am
Its from Durban, Hindian ocean and all!
Title: KLR650 Restoration....Please help......
Post by: Grootseun on May 24, 2007, 09:59:25 am
ahhh... so you can also fit it on your soobie..ek s├?┬¬
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 24, 2007, 10:03:22 am
Guys i plan to fit a powerflow or Bosson later, i just wanna patch it up like a true cheap ass KLR rider would do.  :lol:  :lol:
Title: KLR650 Restoration....Please help......
Post by: Grootseun on May 24, 2007, 10:13:05 am
Contact Jetmaster, and find out what kind of paint they use on their fireplaces/braais and get a small ca, expect to pay . Might not be cheap
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 24, 2007, 10:21:38 am
Quote from: "Grootseun"
Contact Jetmaster, and find out what kind of paint they use on their fireplaces/braais and get a small ca, expect to pay . Might not be cheap


I saw them spray paint a Jatmaster braai on "Riaan Venter's" DIY show on SABC2 last night. Thats where i got the idea from. :D
Title: KLR650 Restoration....Please help......
Post by: lecap on May 25, 2007, 07:56:35 am
Builders Warehouse sells some stuff. Don't remember what it's called. It's black and somewhat heat resistant and meant to refurbish jetmasters and built in braais.

You could maybe also replace some plastics with patches of corroded sheetmetal to match the look of the exhaust  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 25, 2007, 08:51:34 am
Quote from: "lecap"
Builders Warehouse sells some stuff. Don't remember what it's called. It's black and somewhat heat resistant and meant to refurbish jetmasters and built in braais.

You could maybe also replace some plastics with patches of corroded sheetmetal to match the look of the exhaust  :D


Haha very funny. My KLR is a work of art. :lol:   :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 28, 2007, 01:03:03 pm
Okay so i painted the exhaust it looks really nice.

Bought the paint in a spray can at Builder Wharehouse for R95.  :shock:
Luckily it was worth it.

I'll post some before and after pics later.

I also ordered a sticker for my front right radiator cover at R270.  :shock:
Also ordered a clutch cable to keep as a spare on the bike at R70.  :D

Knowing the dealer it will arrive in about two months.  :lol:  :lol:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 28, 2007, 01:21:54 pm
Before......

(http://img150.imageshack.us/img150/9886/before1uc2.jpg)

(http://img296.imageshack.us/img296/2976/before2bz9.jpg)


After......

(http://img147.imageshack.us/img147/1493/aftercr9.jpg)
Title: KLR650 Restoration....Please help......
Post by: IDR on May 28, 2007, 01:24:18 pm
Quote from: "Captain Slow"
(http://img147.imageshack.us/img147/1493/aftercr9.jpg)

REAL men ride KLRs... REAL men don't drink LITE BEER!!!!
 :lol:  :lol:  :lol:  :wink:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 28, 2007, 01:29:19 pm
This real man is really fat, so i have too. :D
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 28, 2007, 02:26:35 pm
Its a KLR mod, lose 10kg is the best way to go faster.
Cheap mod.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 28, 2007, 02:32:27 pm
Quote from: "shark_za"
Its a KLR mod, lose 10kg is the best way to go faster.
Cheap mod.


I'll try and loose 20kgs. I really wanna. Just think how fast the KLR will go then. :lol:
Title: KLR650 Restoration....Please help......
Post by: Groenie on May 29, 2007, 06:39:12 am
I know it's a bit late, but stove polish works well. I used it on the Monty's xorst. Clean it with a wire brush on the drill, and just apply as you would do with normal polish. Nice shiny 'new' xorst....
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 30, 2007, 01:39:14 pm
I cant believe it. The dealer called. My clutch cable and sticker arrived. The best of all is i only had to wait a week.  :lol:  :lol:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 30, 2007, 01:46:57 pm
Lets talk Doohickey?? :D

Okay lets assume my bike still has the genuine Kawa doohickey. I saw in my clymer service manual I should loosen the doohickey bolt under the engine to set the automatic adjuster free. The automatic adjuster will then adjust the chain tension and I can tighten the bolt under the engine again. This should be done every 5000km. I havent done this yet. I?m to scared to touch that bolt.

What do you guys say, should I loosen that bolt or not????? :D



Now lets assume my bike has an Eagle lever aftermarket doohickey. How do you adjust the chain tention on it? Do I have to strip all the covers and stuff out of the motor to get to the doohickey?
Title: KLR650 Restoration....Please help......
Post by: D7 on May 30, 2007, 01:58:18 pm
undo the doo screw half a turn with the bike leaning over to the right side (against a wall). tap the screw gently with a rubber/wooden mallet. retorque to 8.1 (welshie and shark have been thruogh this .1 bit). and hey presto.

in theory that's fine.  

If you have standard doo,  chances are it'll not reset/tighten itself.
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 30, 2007, 02:16:54 pm
Going by experiences, you will do it and nothing will happen.
Most have been bent and are damaged so much that the adjustment procedure does nothing.

I'd suggest you lie it down , take off the cover and see it work for the first time.
But first feel if the engine vibes calm down when you do it normally.
If it does you are lucky. Just dont overtighten the bolt.
Title: KLR650 Restoration....Please help......
Post by: Welsh on May 30, 2007, 02:22:27 pm
Quote from: "shark_za"
Going by experiences, you will do it and nothing will happen.
Most have been bent and are damaged so much that the adjustment procedure does nothing.

I'd suggest you lie it down , take off the cover and see it work for the first time.
But first feel if the engine vibes calm down when you do it normally.
If it does you are lucky. Just dont overtighten the bolt.


Yep, 8.2Nm and it could be it, or is that lbft?

If you feel the vibration has died down, just check it is still running.

Welsh  :twisted:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 30, 2007, 02:32:35 pm
Okay let me ask this. Can one feel the difference between a slack and correctly adjusted chain while riding. My bike feels quite smooth but at certain times it feels like a 160kg vibrator.  :lol:  :lol:
Title: KLR650 Restoration....Please help......
Post by: Grootseun on May 30, 2007, 02:57:00 pm
you know what a 160kg vibrator feels like??? :shock:  :shock:  :shock:  :shock:

wait.. i dont wanna know.... :x

 :D  :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 30, 2007, 03:23:30 pm
Quote from: "Grootseun"
you know what a 160kg vibrator feels like??? :shock:  :shock:  :shock:  :shock:

wait.. i dont wanna know.... :x

 :D  :D



Ja man just ride a KLR.  :lol:
Title: KLR650 Restoration....Please help......
Post by: Welsh on May 30, 2007, 03:54:26 pm
Quote from: "Captain Slow"
Quote from: "Grootseun"
you know what a 160kg vibrator feels like??? :shock:  :shock:  :shock:  :shock:

wait.. i dont wanna know.... :x

 :D  :D



Ja man just ride a KLR.  :lol:


Who was it who described the pleasures of riding a ........versus a KLR, the comment was generally " and suddenly being able to tell that the red blurr in your mirror was really a car!"

Welsh
Title: KLR650 Restoration....Please help......
Post by: D7 on May 30, 2007, 04:43:12 pm
you will defintely know when the doo is loose.

the engine makes a new loud 'knocking' noise,  and the bike has even more vibes than the very many it already has.

after tightening it,  the noise should go away,  and the standard damage to your nerves will continue.
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 30, 2007, 04:44:23 pm
Vibration management is a black art on a KLR.

Tyre pressure and tread pattern, doohickey state, even fuel type seems to affect it.
Title: KLR650 Restoration....Please help......
Post by: Welsh on May 30, 2007, 07:48:14 pm
Quote from: "D7"
you will defintely know when the doo is loose.

the engine makes a new loud 'knocking' noise,  and the bike has even more vibes than the very many it already has.

after tightening it,  the noise should go away,  and the standard damage to your nerves will continue.


So how is the NEW LOUD KNOCKING NOISE, different to the old LOUD KNOCKING NOISES?

Welsh  :D  :D  :D  :D  

Alcohol doesn't solve any problems, but then again, neither does milk.
Title: KLR650 Restoration....Please help......
Post by: D7 on May 30, 2007, 08:06:28 pm
this being a klr,  the old knocking noise is a combo of: mirrors, hand guards, levers, radiator screen, exhaust heat screens, side plastics,windscreen, foorpegs and subframe bolts - oh yes,  and of course the internal combustion thingy :idea: .

when the about mentioned symphony changes in tone,  volume,  clarity,  or when a 'new knocking noise' comes along to the orchestra - do the doo 8)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 30, 2007, 08:45:30 pm
Thanks for all the help.

But i'm still not sure. Bliksem the KLR motor makes a hell of a noise by itself, don't know where to listen for dooo noise. :D

I'll have to open it up sometime and take a look.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 30, 2007, 08:51:31 pm
Okay so one last time just to make sure.

If i install an aftermarket Eagle lever doo it can be adjusted via the external bolt underneath the engine? I don't have to open the engine every time.
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 30, 2007, 11:56:57 pm
Yip, the doo is built to be adjusted from outside.
Just that the standard one ends up broken or dented or with a broken spring.
The eagle part will make the adjust procedure actually do something.

Must hear my KLR engine, its the smoothest one out there.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 31, 2007, 07:07:24 am
Quote from: "shark_za"
Yip, the doo is built to be adjusted from outside.
Just that the standard one ends up broken or dented or with a broken spring.
The eagle part will make the adjust procedure actually do something.

Must hear my KLR engine, its the smoothest one out there.


Nice, how often do you guys do the valve clearances?

Is there a way to listen for incorrectly adjusted valves?
Title: KLR650 Restoration....Please help......
Post by: Welsh on May 31, 2007, 07:41:28 am
Quote from: "shark_za"
Yip, the doo is built to be adjusted from outside.
Just that the standard one ends up broken or dented or with a broken spring.
The eagle part will make the adjust procedure actually do something.

Must hear my KLR engine, its the smoothest one out there.


Except when it loses an exhaust bolt and has the locals diving for cover, as it backfires on the overun.

Welsh  8)  8)  8)
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 31, 2007, 07:55:28 am
Quote from: "Welsh"
Quote from: "shark_za"
Yip, the doo is built to be adjusted from outside.
Just that the standard one ends up broken or dented or with a broken spring.
The eagle part will make the adjust procedure actually do something.

Must hear my KLR engine, its the smoothest one out there.


Except when it loses an exhaust bolt and has the locals diving for cover, as it backfires on the overun.

Welsh  8)  8)  8)


Cool, how do i make my KLR backfire on overrun. I'd like to see the locals dive for cover. :lol:  :lol:
Title: KLR650 Restoration....Please help......
Post by: lecap on May 31, 2007, 08:22:17 am
I do the valves on my KLR's every 12000 km and that proved to be sufficient in the past.
You will not hear any noise indicating the engine is in need of valve adjustment. In general KLR valve clearances tend to decrease over time due to valve seat wear / deformation and the valve drive being virtually wear free. This means you HAVE to check every 10000 or 12000 km or you will sooner or later burn a valve.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 31, 2007, 08:37:58 am
Okay so i need to check those valve clearances too..

How big a job is it to check the valves and what do i need?
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 31, 2007, 09:07:44 am
I've got Tweety living in my exhaust. hehehehe

I'll have to do the hammer and screwdriver mod sometime.

After this thread i'll be a KLR expert.  :lol:  :lol:  :lol:

Tweety is probably hiding from the Cat. :D

(http://img79.imageshack.us/img79/6228/tweetykm6.jpg)
Title: KLR650 Restoration....Please help......
Post by: shark_za on May 31, 2007, 09:09:55 am
Its embarrasing pulling up and people look out for a 1960's VW beetle.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on May 31, 2007, 09:15:33 am
Quote from: "shark_za"
Its embarrasing pulling up and people look out for a 1960's VW beetle.


Yeah. My Tweety lived in the exhaust when i bough the bike.

But now Tweety is getting highly pissed with me and making a big Tweety bird noise. In other words its intruding into my helmet now. I have to get rid of it. I'm killing the bird. :lol:  :lol:

Maybe after i killed the bird i can listen for that Doohickey clapping hands with the balancer chain. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on June 01, 2007, 09:40:58 am
I applied the right hand cover sticker last night.

Its the most expensive sticker i ever saw at R250 so the pressure was on to stick it down properly. :lol:  After lots of fitting and planning it was stuck down.

I mounted the cover on the bike. Pushed the bike back into the garage and went to sleep. This all happened in dark because i had university night classes to attend.

This morning i took the bike out of the garage still dark and i rode to work at a high KLR cruising speed of a 100km/h.  :lol:

I noticed Tweety wasn't yet up, because the exhaust was quite, bike ran smoothly. Everything was lekker.

So got to work, its still dark.

07:30 i pop out of my office to take a look at the sticker job. My what a difference it makes. The bike looks brand new. The newly sprayed exhaust, newly applied stickers and it got a wash and polish yesterday too. :D  :D

I am one happy Captain.  :D
Title: KLR650 Restoration....Please help......
Post by: lecap on June 01, 2007, 10:02:17 am
Doing the valves is pretty straight forward. Normal tools and a feeler gauge. I always set the valves towards the max. allowed clearance which might make the engine mechanically a little bit noisier but it puts you towards the safe side.
Make sure to check the exhaust valve clearance on the right exhaust valve after the decompressor disengages.
The valve cover requires some wiggle to come out and to go in. You have to remove the coil and the cooling fan.

Setting the valves requires a bit more than just checking them as you will have to take the cams out.
I usually only take the journals off and lift the cams a bit and fish and replace the shims with a small longnose plier or tweezers.
Anyway check the timing when you are finished to make sure the chain has not jumped.
A 3/8" drive torque wrench is highly recommended to install the cam journals.
There are shim replacement tools commercially available which wedge in between the cam and the bucket and allow to remove the shims without taking the cam journals off. I don't like them. Too fidgety.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on June 01, 2007, 10:21:59 am
If you guys would suggest a torque wrench, wich one should i buy?

I've got a nice 3/8" socket set to use with it.
Title: KLR650 Restoration....Please help......
Post by: Kev on June 01, 2007, 01:48:04 pm
Quote from: "Captain Slow"
Quote from: "Welsh"
Except when it loses an exhaust bolt and has the locals diving for cover, as it backfires on the overun.

Welsh  8)  8)  8)


Cool, how do i make my KLR backfire on overrun. I'd like to see the locals dive for cover. :lol:  :lol:

 
At least the naught bliksems cannot throw stones at you if they are all diving for cover! Maybe make a guick relase catch to drop the silencer when you go to Lesotho!  :lol:
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on June 01, 2007, 02:21:24 pm
You've got a point there.  :D
Title: KLR650 Restoration....Please help......
Post by: lecap on June 02, 2007, 09:48:11 am
Quote from: "Captain Slow"
If you guys would suggest a torque wrench, wich one should i buy?

I've got a nice 3/8" socket set to use with it.


Hazet. Nothing else. They are bloody expensive (R1000 or so) but see it as a lifetime investment.
I can give you a Hazet part # later.
The wrench goes from 10 to 60 Nm = covers the most important range of stripped bolts & threads on KLR's  :D

I have it's bigger brother (1/2" 10-140Nm) as well but it's not really that essential if you don't work pro. Everything like wheel axles and even rotor bolts you just make lekker tight. Think of 100Nm being 10kg pushing onto a 1m lever to avoid disasters  :lol:

If you buy another one make sure that you can feel the "click" easily even in the lowest torque setting and that you can set it to as little as 10Nm. Also make sure that you can lock the Torque adjustment as soon as it's set to a specific torque.
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on June 02, 2007, 05:15:43 pm
Yes with torque wreches i'll rather pay alot and buy once.

I bought a small 1/4" torque wrench for my work just the other day it cost the company more than R3k. :shock:

Thanks for the advice Le Cap. :D
Title: KLR650 Restoration....Please help......
Post by: El Zeffo on June 04, 2007, 05:01:06 pm
It looks like my coolant overflow problem has been sorted out.

All i did was to idle the bike with the radiator cap off. A few bubbles came out of the open cap and i closed it again.

Did alot of slow offroad riding last weekend and i didn't loose any coolant.
Title: KLR650 Restoration....Please help......
Post by: lecap on June 06, 2007, 10:27:02 am
Always put KLR on paddock stand for work on radiator and cooling circuit.
If you fiddle with the bike on the sidestand you end up with an air bubble in the circuit.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on June 12, 2007, 08:07:19 pm
Its time for the KLR's 5000km service.

So i bought some oil today and an oil filter.

I also bought a new spark plug.

I was just thinking, being the lazy ass that i am..... Is it really needed to change the spark plug every 5000km?
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on June 12, 2007, 08:14:15 pm
Yes with torque wreches i'll rather pay alot and buy once.

I bought a small 1/4" torque wrench for my work just the other day it cost the company more than R3k. :shock:

Thanks for the advice Le Cap. :D

You will not be the first.

Welsh
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on June 12, 2007, 08:17:16 pm
Hmm, I would check it but not change it.
Its not that hard with the tank off.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on June 13, 2007, 06:53:55 am
Hmm, I would check it but not change it.
Its not that hard with the tank off.


Ja but the hard part is to take the tank off.

To drain the oil takes me 10 minutes. If i have to change a plug too it turns into a 1 hour job.  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on June 16, 2007, 03:07:03 pm
Okay so i serviced the KLR.

Clean oil, new oil filter, changed the spark plug.

I also loosened the doohickey for the first time.

I'm glad to say my doohickey is definitely working, because when i loosened it, it made a sound as if it moved to tighten the chain. Then tightened it again and started the bike. Wow what a difference the motor is running smoothly.  ;D

I'm one happy camper.

Service cost me R200.  ;D

Odo now at 47 000kms.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on June 18, 2007, 09:25:49 am
Took the bike to work this morning.

Engine is running as smooth as a hot knife through butter. ;D

No more excessive vibrations on me balls.  :D  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on July 17, 2007, 11:11:06 am
Due to my lack of skill in sand riding i am having to fork out another R525 to restore the KLR....  ;D ;D


Front brake lever R75
Hand guards with aluminum inserts R450

Hopefully these hand guards will last...  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on July 17, 2007, 02:05:53 pm
 :useless:
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on August 14, 2007, 08:36:55 pm
The KLR once again needs some attention.

My rear brakes are shot.

Me thinks i need some new brake pads.
I already replaced the brake fluid and bled the brakes. The brake feels nice and hard but the pads doesn't seem to bite into the disk.

I'll order some pads tomorrow.


The bike is almost at its 50 000km service and i'll need to check the Doo-hickey and do the valve clearances before i leave for my December touring spree....
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on August 14, 2007, 08:41:10 pm
Le Cap what do you think?

Should i check the valve clearances myself and then send it to Kawa for shim replacement or can i do the replacement myself?

Second point, should i trust the Kawa workshop to check the Doo - hickey for me and if damaged replace it with a 2008 doohickey or should i do the doo myself?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on August 14, 2007, 08:50:18 pm
:useless:

Jaja

These are the before pics.....

Still have to take the after pics.....

Notice the "boer maak 'n plan" fix on the hanguard caused by a previous off...  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: D7 on August 14, 2007, 09:22:06 pm
don't trust them with the doohickey
it's such a small job
and they don't know how to do it properly in any event
read the procedure of the marknet site http://www.klr650.marknet.us/
I told them how I wanted it done,  and got looked at like I was a talking fish.

 O0

I'm just waiting for my torque wrench from germany,  then i'll be able to do it home.
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on August 16, 2007, 10:21:20 am
Doing the valves on a KLR is pretty straight forward:

Besides a standard tool set you need a torque wrench and a set of feeler gauges. Make sure that you have 0.05 / 0.10 / 0.15 / 0.20 and 0.25 blades in the set. The torque wrench has to be small enough to fit in between frame and cylinder head. A 3/8" drive is ideal.

Tank off, fan off, coil off.

Clean the area above the cylinder head very thoroughly of all clay, sand, grit and rocks as well as dead insects, small mammals and birds. I'll explain later why this is important. For now just remember that you also brush before you see your dentist.

Loosen the head cover and wiggle it out to the left. Very tight fit.
Check valve clearances. Make sure that the decompressor is not engaged any more when checking Ex R.

Note valve clearances.

Remove plug and spring from cam chain tensioner.
Remove cam chain tensioner ideally without ruining its gasket :)
Count how many clicks are left in your cam chain tensioner (only high mileage engines).
Remove cam chain guide without dropping 8mm socket or small bolt down chain housing.
Remove cam journal blocks again without dropping 10mm socket, bolts or dowel bushes down cam chain housing. The two left blocks come off as one together with the oil gallery pipe.

Turn engine to TDC combustion (cam lobes pointing outwards)

Turn buckets with fingertip until cutout to lift shims becomes visible. Lift cam to allow space for shim extraction and remove shim with very sharp nose pliers or pincers. Small flat screwdriver to pop them up and small magnet also works. Maybe get wife, GF, buddy or neighbour to hold up the camshaft while you fish out the shim.

You do not have to take the timing chain off the cam sprockets to do this!!! The slack you get after removing the tensioner is enough.

If your mechanic is not a muppet the shim should have the nominal thickness on its underside. If it was fitted the other way around you won't be able to read the thickness any more and have to buy a micrometer screw  :-\

Read / measure the shim thickness and calculate the required thickness to get the clearance to the maximum allowed clearance. The Kwak manual has a table for the good looking muppets who were not so good with maths and couldn't do other things too well at school.

This does not make the KLR noticably more clappy nor does it cost noticable amounts of performance.
But KLR valve clearances always close by time which means the sentence "Clappy valves are happy valves" applies 100% to the KLR.

Now phone the nearest Kwak dealer and hope that they have the desired shims. You sometimes are able to move shims from one valve to another and might only need one or two new ones but sometimes you will need all four.
The part numbers run from 12037 - 001 (2.00mm) to 12037 - 025 (3.20mm)

Do NOT leave your old shims at the dealer unless they offer you a reasonable discount for "exchange" (like I do). The shims do not wear at all and they likely sell you the ones they pulled out of your friends KLR at the last service (like I do).
If the Kwak dealer does not have stock (yes, this does happen sometimes)you can try your luck at BMW. Apparently the K75 valve shims are a fit. Some sources also claim some Toyota parts being suited. I have not confirmed either.

In extreme emergencies you can of course phone me. I have stock of all sizes of KLR shims and will courier them overnight. I stock at least four each of the most common sizes between 2.30 and 2.65 and two or three of the rest of the range. Plus a few "specials" of 195 and 190 to extend buggered heads lifespans a bit.

Once you have your shims you can fit them. Make sure that you told your wife, GF, buddy or neighbour that they can put down the camshaft after removal of the shims otherwise they might be pissed of with you by now (or might have starved to death or left you and filed for divorce).

Insert the shims with the thickness mark facing down (remember, you ain't a muppet, right?) Make sure they go into place and that there's no crap between shim and bucket. See clean before start above. The shim won't fit properly with a dead bird trapped underneath it.

Once all shims are in you can fit the cam journal blocks and tighten them to the specified torque. Compress the cam chain tensioner completely by lifting the arrestor and pushing the plunger in. Fit the cam chain tensioner and then the tensioner spring and cap and check the timing marks. Crank the engine by hand a few turns to make sure the shims are seated 100% and check your valve clearances.

If your clearances are not where you intended them to be go and ask your kids how to add and subtract and start all over.

If everything is fine clean out all the gunk that accumulates around the head cover bolts and their rubber seals, wiggle the head cover back on (like on extraction preferably without doing damage to the rubber seal).
Do not use any gasket maker or other s**t on these rubber seals. It won't help. If they leak they are buggered or old. Replace.
Use a torque wrench to tighten the head cover bolts. These threads are often stripped!

Fit everything you removed earlier and that seems important to your riding (not the dead animals).

Valves done!

Instead of replacing the old pre2007 doohickey with the 2008 version I would rather go for the Eagle Lever which has a proven track record. It will probably cost you some 100Rand more than the OEM2008 doo but for those 100odd rand extra you get total peace of mind. Remember that over 23 years of production of the KLR 600 / 650 Kawasaki never admitted a problem with the balancer shaft idler lever. Although the new Kawasaki doo is stronger than its predecessor it's still welded from sheetmetal and a far cry from the cut out of a block eagle lever.
Title: Re: KLR650 Restoration....Please help......
Post by: buzzlightyear on August 16, 2007, 11:06:20 am
Well done lecap. Now if someone cannot do it after all that, they should take it to you ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on August 21, 2007, 01:47:05 pm
I installed my new SBS rear brakepads. Have to run them in now and see if it makes a difference.

Cost R160.
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on August 22, 2007, 08:58:00 am
OEM, SBS, EBC, Ferodo all seem to be ok.
Emgo are bricks and wear down the discs.
Rather go with soft pads (most good quality aftermarket pads) and replace more frequently than replace discs.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on August 22, 2007, 09:56:50 am
I'm busy running in the pads, i can feel an improvement. Hopefully when run in properly the pads will stick.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on August 30, 2007, 05:23:07 pm
Jippeee the KLR brakes are working again.

The new SBS pads solved my problem.

I can lock the rear up whenever i like...  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: sidetrack on September 02, 2007, 02:57:00 pm
OEM, SBS, EBC, Ferodo all seem to be ok.
Emgo are bricks and wear down the discs.
Rather go with soft pads (most good quality aftermarket pads) and replace more frequently than replace discs.

Ever seen those Emgo piston kits, something like R150  :o
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 04, 2007, 07:41:48 pm
I installed my new hand guards a while ago and havent posted pics yet... here goes...

(http://i198.photobucket.com/albums/aa313/heinb7/04092007351Medium.jpg)

(http://i198.photobucket.com/albums/aa313/heinb7/04092007350Medium.jpg)

I also installed an Aerotrim wind deflector...

(http://i198.photobucket.com/albums/aa313/heinb7/04092007349Medium.jpg)
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on September 04, 2007, 07:53:10 pm
Verdict on the wind deflector?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 04, 2007, 08:09:58 pm
Verdict on the wind deflector?

Havent tested it.... got home and installed it... will test tomorrow on my way to work.  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: roburt on September 05, 2007, 11:59:21 am
Verdict on the wind deflector?

Havent tested it.... got home and installed it... will test tomorrow on my way to work.  ;)

i think there will be a few klr guys waiting for this test.
Title: Re: KLR650 Restoration....Please help......
Post by: D7 on September 05, 2007, 04:46:01 pm
just take the entire windshield thingy off
now,  the wind hits me in the chest - helmet is in 'clean air'
much less wind noise too...

R0.02
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 05, 2007, 06:01:42 pm
just take the entire windshield thingy off
now,  the wind hits me in the chest - helmet is in 'clean air'
much less wind noise too...

R0.02

Duly noted thanks  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: roburt on September 06, 2007, 09:27:59 am
I installed my new SBS rear brakepads. Have to run them in now and see if it makes a difference.

Cost R160.

Mr Stadig

Do you perhaps still have the part number for your rear brake pads, I am trying to get some but the guys i'f been to seem to be confused. First went to Kawasaki hatfield , they sold me sbs pads for R180  :o and then tried to fit it and saw that the smaler pad is to small, took it back and they said oohh i think its other pads  ??? , then went to biking accesories, they had ferodo's for R60 but the guy also told me he knows there is 2 types.
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on September 06, 2007, 09:31:39 am
Think you need an FA67. Will check at the shop just now and edit later.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 06, 2007, 10:23:40 am
No sorry i don't know the part number... just asked for KLR brake pads and they sold them to me..
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 06:55:26 am
Last week i removed the front fairing on the KLR to set my headlight.... it was aiming way to high....

Noticed the little bracket controlling the vertical position was broken... i'll strip it down and weld it back together...  ;D

I'll try to take some piccies...  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: roburt on September 07, 2007, 09:28:09 am
Think you need an FA67. Will check at the shop just now and edit later.

got the pads yesterday from Mean Machine Menlyn (paid R145 -- strange that hatfield charges R180). Anyway fitted it and lets see how they work after the have been ridden in.

PS : Thanks for the winddeflector KLR test.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 09:40:46 am
Think you need an FA67. Will check at the shop just now and edit later.

got the pads yesterday from Mean Machine Menlyn (paid R145 -- strange that hatfield charges R180). Anyway fitted it and lets see how they work after the have been ridden in.

PS : Thanks for the winddeflector KLR test.

It will take about 3 days to let the pads bed before they work properly...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 09:43:14 am
I used this procedure to bed my pads.... works like a charm... ;)

Credit to Richard from BikeSA for this...





How to break in brake pads. You basically cycle them.

You want to avoid severe braking with new parts until they are bedded in. The old wives tale of going out and doing some "panic" stops from 140 is NOT what is recommended to bed new brake parts.

1. Find a deserted stretch of road and accelerate to about 50kph and then apply moderate pressure. Don't stop completely and sit with the pads stationary on the rotor, just brake to about a 95% stop, roll out and re-accelerate to about 50kph. Stop again the same way. Repeat this step about 10 times.

2.Then ride off to cool everything down

3.Now at about 70 kph apply hard pressure to a 95% stop. Repeat this step about 5 times.

3. Continue riding for about 15min without using that brake to allow it to cool completely the new brake pads.

It is important to bed them like this to mate the parts together, optimize the contact patch between the pads and rotors, get the parts up to high temp to clean off any volatiles from the manufacturing or handling process and to transfer a bit of the pad material to the rotor surface for optimum friction characteristics. The stops should be hard but not panic and not hard enough to activate the ABS, if fitted. Just a good, firm, hard stop to generate heat in the brakes.

It is much better for the brakes to bed them in purposefully like this than to just ride and do it with various gentle stops as the temp will not be there and it will take much longer......and you risk damaging the brakes without even knowing it with a panic stop in an unforeseen emergency in the meantime.

You don't want to come to a hard stop each time during the bed-in and sit with the pads held against the rotors as that will cause non-uniform pad material transfer to the rotors and potential heat damage, since the hot pad will insulate the hot rotor in that spot and uneven cooling will result. Just roll out the stop each time and accelerate back to speed for the next one.
Title: Re: KLR650 Restoration....Please help......
Post by: roburt on September 07, 2007, 10:07:14 am
cool i will do that (bliksem maar dis maklik om brakepads te vervang.... vat langer om die tools te kry)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 10:46:56 am
cool i will do that (bliksem maar dis maklik om brakepads te vervang.... vat langer om die tools te kry)

hehe ja  ;D

Sit net klein biekie blou locktite op die twee bracket boute...  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 10:53:24 am
Quick tea time job..  ;D

Removed front headlight and welded broken bracket...  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on September 07, 2007, 12:12:34 pm
Heirdie fred is al so lank, mens sal dink jy het al meer bling op jou KLR as Shark of Kilroy ... ::)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 12:16:13 pm
Heirdie fred is al so lank, mens sal dink jy het al meer bling op jou KLR as Shark of Kilroy ... ::)

Jislaaik Groenie... my KLR lyk nou al mooi jong... ek is mal daaroor om hom reg te maak... julle moet onthou hy het amper 50 000km op en dis 'n 2005 model.  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on September 07, 2007, 12:22:13 pm
Dis hoekom ons KLR's ry. Elke ding wat jy self doen laat jou net nog meer geld spaar op hom
Title: Re: KLR650 Restoration....Please help......
Post by: D7 on September 07, 2007, 12:57:42 pm
hey Cpt
mine broke in the exact same place.
looks like another KLR weak point...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 01:04:18 pm
hey Cpt
mine broke in the exact same place.
looks like another KLR weak point...

Jip but i made sure its not going to break there again..  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: roburt on September 07, 2007, 01:58:03 pm
this tread is a very very usefull one for everyone starting on a klr....it covers a lot of stuff  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on September 07, 2007, 02:04:54 pm
With inputs from lecap, D7 , Kilroy, Groenie, and a few non KLR gurus like Welsh, this is a good starting point for all KLR buyers.
Even Capn's own experiments and stuff are valuable.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 07, 2007, 02:14:34 pm
I love this fred..  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 09, 2007, 09:05:12 pm
Popped my clutch release lever seal today on a run.  >:(

Please tell me i can replace the seal without taking the engine side cover off?  ???

I added a picture to avoid confusion.  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on September 10, 2007, 07:44:35 am
I never even heard of that seal going.
Not sure if you can do it with the clutch cover in place.
Don't think so.
Will have a look later at the shop and let you know.

I have the clutch cover gasket in stock.

If your bike is 50000km or more consider doing the water pump shaft seals as well while you're at it.
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on September 10, 2007, 10:40:01 am
My KLR's seal was damaged in a fall before I bought the bike. I shoved some Pratley Steel around the affected area as a get me home fix and have been riding like that for the last 6k kilometres with only a slight oil weep. Been meaning to change it and have even bought a replacement clutch cover etc. but somehow have never gotter round to doing it.

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 10, 2007, 12:39:18 pm
Thank you for the response Le Cap. I'll do the clutch seal and the waterpump seals later. I'm first going to the Springbok rally... The leak isn't bad...

Does the KLR have sump breather pipes, maybe mine is blocked or something?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 10, 2007, 06:04:28 pm
Its easy to get the clutch release shaft out....

Just remove the clutch cable and turn the shaft backwards and pull...  ;D

Cant see anything wrong with the seal... but i'll replace it anyway. I'll get one from an engineering shop, i'm not waiting 6 weeks for a Kawa dealer.  ;)

Oh yes buy the way the seal is still stuck in the bike can't get it out.... but i suppose it wont come out while the bike is hot..  :D Will wait till tomorrow... when bike is cold...

The manual says i must pry the seal out of its hole with a screwdriver... hmmm a stressful operation...   ::)
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on September 11, 2007, 08:48:17 am
Your camera does not want to do macro?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 11, 2007, 09:02:33 am
Your camera does not want to do macro?

Huh??

Its a cell phone camera, it only focus properly when it feels like it..  :-[
Title: Re: KLR650 Restoration....Please help......
Post by: aerotrim designer on September 11, 2007, 07:50:31 pm
Hi all KLR and KLE riders we have just had news that our screen for these models are perfected and yes Captain slow you will shortly receive on of the latest bigger screens for free.
Soon one of the members will drop a post regarding the new design.So all the klr and kle owners here is your chance to have the same effect as the other ktm and GS riders.
Are there any varaderos and v-stroms out there ..............you are missing out big time!!!!

Keep the revs up.
Jacques
www.aerotrim.co.za
083 7787898
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 11, 2007, 08:04:44 pm
Thanks Jacques  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 12, 2007, 09:25:12 am
Guys i'm struggling to get that seal out. I'm busy getting a special tool made to release the seal from the hole..  :-[
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on September 12, 2007, 11:21:31 am
Wouldn't it be easier to remove the clutch cover? I'm not convinced that that seal is supposed to come out that way.
Title: Re: KLR650 Restoration....Please help......
Post by: roburt on September 12, 2007, 01:05:58 pm
Thanks Jacques  ;D

keep us posted on how the new screen works
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 12, 2007, 03:12:56 pm
Wouldn't it be easier to remove the clutch cover? I'm not convinced that that seal is supposed to come out that way.

To take the side cover off you need 2 new gaskets and new oil, thats gonna cost me at least R400..  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on September 12, 2007, 03:15:35 pm
Kannie dit toelaat nie! Kan jy nie die olie weer gebruik nie?    ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 12, 2007, 04:00:34 pm
Kannie dit toelaat nie! Kan jy nie die olie weer gebruik nie?    ;D

Nee Groenie... ek gebruik nie die olie weer nie...  :D

Die olie is in elkgeval nie die probleem nie die gaskets is...  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 13, 2007, 08:11:50 am
Making the seal puller.  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 13, 2007, 09:34:41 am
The super seal puller tool is finished... hope it works..  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 25, 2007, 04:38:32 pm
Guys i could not get the seal out... it was put in with Loctite...  >:(

But i rode about 900kms this weekend and suddenly it doesn't leak anymore so i am happy.  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: D7 on September 25, 2007, 04:41:13 pm
you need a heat gun,  to break the loctite
and to get new seals in there asap.
remember what happened to shark's KLR...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 25, 2007, 04:43:12 pm
you need a heat gun,  to break the loctite
and to get new seals in there asap.
remember what happened to shark's KLR...

I've got a heat gun...

What happened to Shark's KLR?? :o
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on September 25, 2007, 05:04:27 pm
What happened to my KLR?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 25, 2007, 05:06:59 pm
What happened to my KLR?


Yes..  :D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 25, 2007, 05:57:25 pm
your rear bearing hassle???

the one Welsh helped you with...

or maybe I am still mad...

Are we still talking about stuff that can be caused by my KLR's faulty oil seal..  ::)
Title: Re: KLR650 Restoration....Please help......
Post by: D7 on September 25, 2007, 06:04:45 pm
oops
my bad

do your bearings though,  lad

(all the talk of the tech day & bearings seems to have me sidetracked...)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 25, 2007, 06:10:44 pm
oops
my bad

do your bearings though,  lad

(all the talk of the tech day & bearings seems to have me sidetracked...)

What bearings??

Wheel bearings??  ???
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on September 25, 2007, 06:14:39 pm
Oh, my sprocket carrier bearing gave up.
Replaced them all (2x rear and carrier, 2x front) with sealed units.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 25, 2007, 06:15:57 pm
Oh, my sprocket carrier bearing gave up.
Replaced them all (2x rear and carrier, 2x front) with sealed units.


Ahhhh okay  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on September 28, 2007, 07:16:59 am
My wonder rear tyre..

Its done 7000km mostly on tar and its still got 2mm till the legal limit left.

Its called SHINKO TRAIL TIRE...  :D
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on October 01, 2007, 09:29:49 am
I know them. They are great offroad as they are hard as a log. I once sold one of my DR's to a lady from Denmark who went to Dar and back. She came back with the Shinko Shonko tire which I believe she bought in Arusha. Had wiped out on almost straight wet tar only from opening up. Luckily only at the cost of a few bruises and some scratched handguard & front mudguard.

I envied Mrs LeCap for the Kings Claw Action KT966 I fitted to her Djebel200 before our trip while I was all over the show with the DR's OEM Bridgestones.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 01, 2007, 09:40:57 am
I had no problems with grip from the Shinkos... but then again i've got nothing to reference it to..  :D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 19, 2007, 06:00:52 pm
I bought a new rear Anakee for the KLR and took the wheel of to take it to the shop for fitment tomorrow.

I checked my wheel bearings, they still seem perfect. Should i really change them?? Cant i just smear some grease on the old ones and put the wheel back on the bike?

On the point, how did you guys get your wheel bearings out. Clymer shows some special tool that i don't have. Any tips??
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 19, 2007, 06:02:04 pm
Groenie my special bottle jack lift is working... :D
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on October 19, 2007, 07:09:44 pm
I bought a new rear Anakee for the KLR and took the wheel of to take it to the shop for fitment tomorrow.

I checked my wheel bearings, they still seem perfect. Should i really change them?? Cant i just smear some grease on the old ones and put the wheel back on the bike?

On the point, how did you guys get your wheel bearings out. Clymer shows some special tool that i don't have. Any tips??

A stand to put the wheel on, most workshop stands like the one the puppy is lookin at have a hole in the middle.

(http://i12.photobucket.com/albums/a236/IWelshman/DSC01952.jpg)

This gives a nice stable platform to work from.

No special tools needed, unless you regard a loooong screw driver / drift an a hammer etc as special tools, of course an internal circlp pliers ( I fink R35 at Builders rip off).

Welsh  8) 8) 8)

 Anti-wrinkle cream there may be, but anti-fat-bastard cream there is none.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 19, 2007, 07:56:56 pm
Welsh i like that dog.
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on October 19, 2007, 08:04:59 pm
Welsh i like that dog.

When he playfully runs through/past you chasing the other dogs through a gateway and hits you behind the knee, you dont love him for a while!!!!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 19, 2007, 08:06:48 pm
Welsh i like that dog.

When he playfully runs through/past you chasing the other dogs through a gateway and hits you behind the knee, you dont love him for a while!!!!

I know the feeling
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on October 19, 2007, 08:16:03 pm
As a puppy (left) he was cute, but he grew a bit!!!

(http://i12.photobucket.com/albums/a236/IWelshman/Picture002.jpg)
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on October 20, 2007, 08:45:47 am
I bought a new rear Anakee for the KLR and took the wheel of to take it to the shop for fitment tomorrow.

I checked my wheel bearings, they still seem perfect. Should i really change them?? Cant i just smear some grease on the old ones and put the wheel back on the bike?

On the point, how did you guys get your wheel bearings out. Clymer shows some special tool that i don't have. Any tips??

Yes, change the bearings Cappie. They are only sealed on the outside, replace them with double rubber sealed bearings. I was riding behind Shark when his bearings failed. Not a good thing to have happen, chain was jumping all over, skipping teeth and the whole rear wheel seemed to be wobbling.

Actually quite easy. There's a spacer between the 2 bearings, that can move a little sideways. Push it to the side and use it to bliksem the 1st bearing out. Then you'll have access to the other one. Easy, Kilroy could do it....
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 20, 2007, 10:13:34 am
Welsh pragtige honde...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 20, 2007, 10:16:33 am
Okay i'll change the bearings after all i allready bought them.

Fitted the new tyre this morning and went for a ride to get rid of all the slippery stuff on the tire. Did a few tight turns and all the silicone is gone.

Man did i vloek this morning setting the chain. Any tips on setting the chain. I sat on the bike and the chain still had some play so i think its set right. Those chain adjuster screws are very sensitive.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 20, 2007, 11:07:15 am
KLR bottle jack lift... patents pending..  :laughing4: :laughing4: :laughing4:

Two empty paint tins included with every unit...  :laughing4: :laughing4: :laughing4:
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 20, 2007, 11:09:46 am
My two babies....

KLR fitted with new tire.  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on October 21, 2007, 10:08:51 am
On the point, how did you guys get your wheel bearings out. Clymer shows some special tool that i don't have. Any tips??

Actually quite easy. There's a spacer between the 2 bearings, that can move a little sideways. Push it to the side and use it to bliksem the 1st bearing out. Then you'll have access to the other one. Easy, Kilroy could do it....

Do not use the spacer to remove the bearings. It's made from mild steel and suffers quickly. The result will be your new bearings not seating properly and wearing rapidly.
Lever the spacer out of alignment with an old long flat screwdriver or a driver made from some 12mm or so steel round bar until you can get your driver onto the inner race of the wheel bearing on the other side of the wheel and drive the bearing out.

Removing the wheel bearing only gets tricky once the bearing has started to disintegrate.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 21, 2007, 11:17:23 am
I love my Anakees the corner very well... i'm one happy chappy.
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on October 21, 2007, 06:37:38 pm
On the point, how did you guys get your wheel bearings out. Clymer shows some special tool that i don't have. Any tips??

Actually quite easy. There's a spacer between the 2 bearings, that can move a little sideways. Push it to the side and use it to bliksem the 1st bearing out. Then you'll have access to the other one. Easy, Kilroy could do it....

Do not use the spacer to remove the bearings. It's made from mild steel and suffers quickly. The result will be your new bearings not seating properly and wearing rapidly.
Lever the spacer out of alignment with an old long flat screwdriver or a driver made from some 12mm or so steel round bar until you can get your driver onto the inner race of the wheel bearing on the other side of the wheel and drive the bearing out.

Removing the wheel bearing only gets tricky once the bearing has started to disintegrate.

We did  it automatically never considerred the spacer, but I am a tool sale addict so I have lots of looong screw drivers.

Welsh
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 25, 2007, 12:07:48 pm
Fitted my footpegs today... i love em  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 25, 2007, 05:18:03 pm
Just added Aerotrim MK2
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on October 25, 2007, 07:17:00 pm
Werk daai Aerotrim magaftertjie regtig?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 25, 2007, 09:17:47 pm
Werk daai Aerotrim magaftertjie regtig?

Weet noggie sal bietjie toets en laat weet.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on October 31, 2007, 05:44:55 pm
Look what came in the post today....  :o :o :o






Thanks Le Cap  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 06, 2007, 12:15:00 pm
A few quick doo hickey questions??  :P

Do you guys remove the front sprocket when doing the doo?

I suppose i should put some oil on the puller thread while using it? What oil?

My Doo came with 2 springs... should i use the long or the short one?
Title: Re: KLR650 Restoration....Please help......
Post by: roburt on November 06, 2007, 04:12:16 pm
groenie is the main expert...but with me doing mine with him bedhind me I will give some advice.

1. No, you do not need to remove the front sprocket.

2. Yes we used some of the oil from the engin bay when we put the bolt in, make sure you have someone to help you hold the bike when you put the bolt in.

3. you will have to see what spring fits best when you hook it into the dooh.

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 06, 2007, 04:22:16 pm
Guys i found a shop to do the doo for me... i'm not going to bother.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 09, 2007, 11:39:17 am
Seeing Groenie's KLR made me fall in love with KLRs all over again.

I also noticed mine needs some work in the performance department.

So let the mods begin ;D




Disclaimer: Mods can only happen as fast as my gatsak or beer budget can finance the mods so be patient, i'm not called Captain Slow for nothing. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 10, 2007, 09:08:15 am
I'm checking the valves today. So i'm off to go buy a feeler guage. ;D  Oh yes and some grease for da wheel bearings.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 10, 2007, 09:24:06 am
Wasn't you supposed to do the doo today?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 10, 2007, 12:06:31 pm
Wasn't you supposed to do the doo today?

Next week i'm taking the bike in to a workshop. Doo and valves at the same time.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 10, 2007, 12:09:27 pm
Checked the valves.

Exhaust left: 0.13mm
Exhaust right: 0.13mm
Inlet left: 0.10mm
Inlet right: 0.08mm

All out of spec but at least i have some gap left.  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 10, 2007, 06:10:37 pm
Holes in the airbox  ;D

Also noticed my one exhaust mounting bolt is missing  :o :o Obviously forgot to put loctite on it  :D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 10, 2007, 06:37:30 pm
Ah, I'm mystified about the holes in the airbox, what are they for?

Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 10, 2007, 06:37:43 pm
I'm checking the valves today. So i'm off to go buy a feeler guage. ;D  Oh yes and some grease for da wheel bearings.

You do not need grease for the wheel bearings, you need sealed wheel bearings....
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 10, 2007, 06:40:25 pm
Ah, I'm mystified about the holes in the airbox, what are they for?



Try breathing through a straw?
Thats what bikes do, due to noise regs etc, Da holes let it breath.. Big Breaths  "yeth and im only thixthteen"..

Welsh   8) 8) 
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 10, 2007, 07:26:00 pm
I'm checking the valves today. So i'm off to go buy a feeler guage. ;D  Oh yes and some grease for da wheel bearings.

You do not need grease for the wheel bearings, you need sealed wheel bearings....

Okay... haha i've got the bearings and now i've got some grease too ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 10, 2007, 07:28:44 pm
Ah, I'm mystified about the holes in the airbox, what are they for?



Try breathing through a straw?
Thats what bikes do, due to noise regs etc, Da holes let it breath.. Big Breaths  "yeth and im only thixthteen"..

Welsh   8) 8) 

You can clearly hear the difference the holes make.... still the wind is blowing so f*#king strong in PE i can't do a top speed run to see if it makes a difference.


Bhahahaha coming home just now the bike backfired for the first time... hehe all i need is a lekker pipe, airfilter and carb tweaking.... bystanders will duck for cover... ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 11, 2007, 05:44:36 pm
I found the best KLR screen... no screen... thanks D7  ;)

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=11864.0;attach=6209;image)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 11, 2007, 05:46:49 pm
The holes in the airbox makes a nice sound as you ride. I'll recommend it to anyone.

The best of all the bike gets its air from right under you poephol which means a fart works like Nitrous ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 11, 2007, 07:22:25 pm
I found the best KLR screen... no screen... thanks D7  ;)

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=11864.0;attach=6209;image)

Check my post today, no screen, I really do not think it is an advantage it directs the air up to buffet your helmet... without it there is less buffeting!!!!!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 11, 2007, 08:00:03 pm
Correct there is no buffeting without the screen.... but the windblast on ones chest is really bad at 120 and above. Therefore i'll ride the bike without a screen but if i hit long distance i'm going to put the screen back. Only takes 2 minutes to fit anyway.
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 11, 2007, 08:13:54 pm
Correct there is no buffeting without the screen.... but the windblast on ones chest is really bad at 120 and above. Therefore i'll ride the bike without a screen but if i hit long distance i'm going to put the screen back. Only takes 2 minutes to fit anyway.

So there not lying? at sea level will a KLR dooo 120???
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 12, 2007, 07:11:07 am
Correct there is no buffeting without the screen.... but the windblast on ones chest is really bad at 120 and above. Therefore i'll ride the bike without a screen but if i hit long distance i'm going to put the screen back. Only takes 2 minutes to fit anyway.

So there not lying? at sea level will a KLR dooo 120???

Ja man it does 170 with a downhill.. :grin:  A loooooonnnnggggg downhill hehe
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 13, 2007, 10:38:10 am
My bike is currently in the workshop for the doo and the valve shims.

The mechanic gladly pointed out to me that my standard KLR gear lever has a long crack in it and its about to fall off..  :D

KLR so predictable...  :downtown:
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 13, 2007, 04:49:38 pm
KLR doo done... spring broke... doo still original and fine... 52000km on the clock

Valve clearances done.

Bike starts easier and runs as smooth as butter... like a new KLR...

I was warned that my Cam chain tentioner is almost at max.  :o

Very happy

 :blob10: :blob3: :blob5: :blob10: :blob3: :blob5:

 :bootyshake: :bootyshake:

 :fart: :downtown:
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 13, 2007, 04:51:59 pm
Oh yes and one gearlever welded up again ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 13, 2007, 07:00:38 pm
Oh yes and one gearlever welded up again ;D

I thought WOW a mechanic with eyesight how unusual.....

Welding a piece of KAK gives you a welded piece of KAK, I fink they are 250 rund for the good one, go do it...

Welsh  ;D ;D ;D ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 13, 2007, 07:15:48 pm
Oh yes and one gearlever welded up again ;D

I thought WOW a mechanic with eyesight how unusual.....

Welding a piece of KAK gives you a welded piece of KAK, I fink they are 250 rund for the good one, go do it...

Welsh  ;D ;D ;D ;D

Jaja i'm broke at the moment... no money no gear lever ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 13, 2007, 07:31:35 pm
Hi Captain.

Glad to hear the doo's done. And there you have it. If you had followed the procedure for setting the tesion on the chain during a service, it would have been no help, so good going there.

Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 14, 2007, 10:14:55 am
Oh yes and one gearlever welded up again ;D

Heya Cappy! Someone was advertising a KLR g/lever on the Pay Kit Forward thread...go have a look!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 10:23:11 am
Oh yes and one gearlever welded up again ;D

Heya Cappy! Someone was advertising a KLR g/lever on the Pay Kit Forward thread...go have a look!

I'll have a look but i'm broke at the moment. Thinking about getting one from Le Cap.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 02:34:35 pm
I need some advice..

How can i redo the front part of my KLRs exhaust pipe??

Maybe sandblast and then powder coat it light grey or black?? Paint doesn't last on it.

What do the guys do that restores classic cars? They have colour coded exhausts don't they?  ::) ::)

Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 14, 2007, 03:25:14 pm
Get some expensive High heat paint and give it a couple of layers, or ( I don't know if you can still get it) some stove polish that used to be used on the old wood/coal stoves? We used  it on our enduro bikes......(showing my age here)  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 03:59:28 pm
Get some expensive High heat paint and give it a couple of layers, or ( I don't know if you can still get it) some stove polish that used to be used on the old wood/coal stoves? We used  it on our enduro bikes......(showing my age here)  ;)

I used the high heat paint on the exhaust it didn't last very long. Go back a few pages in this thread and you will see.

The guys at my work reckon black etch primer would last better as we use it on our boilers.
Title: Re: KLR650 Restoration....Please help......
Post by: bobnob on November 14, 2007, 04:00:28 pm
you will have to get yourself a new header made

not much you can do with that pipe
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 14, 2007, 04:08:00 pm
Quote
The guys at my work reckon black etch primer would last better as we use it on our boilers.

Can you find out more about this? Sounds interesting...
Does anyone still do black-chroming?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 04:09:12 pm
you will have to get yourself a new header made

not much you can do with that pipe

Okay.. will a place like Powerflow be able to copy that one in Stainless steel if i take it to them?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 04:11:56 pm
Quote
The guys at my work reckon black etch primer would last better as we use it on our boilers.

Can you find out more about this? Sounds interesting...
Does anyone still do black-chroming?

Our maintenance team paints the outside panels of our coal fire boiler with the black etch primer and it seems to last a year at a time.

I'm going to replace the rear part of the exhaust with a Penta but i thought i could save the front piece with some paint. It looks really k*k.
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 14, 2007, 04:18:30 pm
Quote
I'm going to replace the rear part of the exhaust with a Penta

Eish!! Sorry wallet.......(alweer) Daar gat jou Xmas bonus al klaar!!! 8)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 04:18:56 pm
This was done in May.... look how nice the pipe looked... all that paint is gone now.  :'(

Before......

(http://img150.imageshack.us/img150/9886/before1uc2.jpg)

(http://img296.imageshack.us/img296/2976/before2bz9.jpg)


After......

(http://img147.imageshack.us/img147/1493/aftercr9.jpg)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 04:20:17 pm
Quote
I'm going to replace the rear part of the exhaust with a Penta

Eish!! Sorry wallet.......(alweer) Daar gat jou Xmas bonus al klaar!!! 8)

Ek kannie anders nie... my exhaust het vir Tweety bird ingesluk en ek wil begin met performance mods soos Groenie se bike.
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on November 14, 2007, 09:10:14 pm
Gewone "stove paint" werk ook goed. Het vergeet daarvan toe ek daar by jou was. Btw. thanx vir die hulp.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 09:31:02 pm
Gewone "stove paint" werk ook goed. Het vergeet daarvan toe ek daar by jou was. Btw. thanx vir die hulp.

Stove paint?? Is dit nou black etch primer?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 09:31:47 pm
Groenie moes jy iets verander om Pro tapers op jou bike te mount?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 14, 2007, 09:35:53 pm
Gewone "stove paint" werk ook goed. Het vergeet daarvan toe ek daar by jou was. Btw. thanx vir die hulp.

My plesier, dankie vir die doppe en die Eisbein... hmmm ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 17, 2007, 02:43:20 pm
Found my battery is without electrolyte... gonna buy some stuff tomorrow to fill it..

Now the question, what must i buy to put in there?  ???
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 17, 2007, 02:45:44 pm
Ahhh the doo hickey replacement... it totally changed the bike. Now the engine is smooth and it almost sounds like a 650 GS... which is a terrible sound so i'll have to change it ;D

The engine now goes whhiiiissssss rather than bababababababa ;D
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 18, 2007, 07:54:25 am
By the way Cappy, how does your screen/wind deflector work?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 18, 2007, 09:28:20 am
By the way Cappy, how does your screen/wind deflector work?

;D

Okay let me spill the beans.

I thoroughly tested the screen. I rode with it and without it for a while.

Screen definitely makes a difference.

The million dollar question: Am i happy with it?      NO...

My suggestion: Buy a big proper KLR touring screen. 
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 18, 2007, 11:40:36 am
I just can't stop talking about the big difference the doo hickey mod made to the bike. The engine feels and sounds brand new.

Yesterday i put my screen back on and took the bike for a ride. With the screen and the doo conversion the bike feels like riding a coach, can't wait to take it on the long road in December.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 18, 2007, 11:52:46 am
Changes i made to the bike so far:

Michelin Anakee tyres
T-Mod
Front brake disk and brake pads
Rear brake pads
Bled brake fluid
Changed some spokes
Replaced clutch friction plates
Sticker on right radiator shroud
Doo hickey
Valve shims
Foot pegs
Airbox conversion
Clutch lever
Brake lever
Hand guards
Coolant
Aerotrim screen


I also repaired a few items on the bike.


The following has to be done in December:

New sealed wheel bearings
New sprockets
New o-ring chain
New clutch cover gasket
New waterpump gasket
Coolant
New clutch cable
New fork seals and fork oil
Fitment of Penta Exhaust

On the list for future mods:

IMS tank
Fork springs
Dirt bags and mountings
Bashplate
Stainless front brake line
Airscrew and needle mod
Protaper bar and raisers
Power point and compressor

and the last mod i'll ever dooooo GPS ;D
 ::)
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 18, 2007, 12:14:38 pm
You been a busy man!!!
I've just given mine a good wash and clean up, after a very wet and muddy ride yesterday! But it was great fun! I've found a broken exhaust bracket and that there is a loose baffle plate in my (standard) muffler  >:(
So guess who's gonna be doing motorbike 101 instead of chainsaw 101 at work tomorrow?? Hehehe

PS Those standard mufflers are &*#@ heavy!!!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 18, 2007, 12:53:22 pm
You been a busy man!!!
I've just given mine a good wash and clean up, after a very wet and muddy ride yesterday! But it was great fun! I've found a broken exhaust bracket and that there is a loose baffle plate in my (standard) muffler  >:(
So guess who's gonna be doing motorbike 101 instead of chainsaw 101 at work tomorrow?? Hehehe

PS Those standard mufflers are &*#@ heavy!!!

Ja ek sê jou.. gemaak van swart pot yster ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 03:36:26 pm
Hi its me again

I need some help.

I want to redo my front shocks on the KLR.

Change the fork seals, put in new oil and while the front wheel is off replace the wheel beerings.

Some questions:

1. Do i need special tools to change the forkseals?
2. What oil should i buy for the front? 10W, 15W?? I want to make the front firmer.
3. How much oil should i buy?

HELP PLEASE???

 ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 04:23:54 pm
Seems like 10W oil is in order and 1 litre of oil should be enough...

Also looks like i can blow the seals out with compressed air after i removed the oil off coarse ;D
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 19, 2007, 04:26:50 pm
Here's something else you can look at while your banger is on blocks... I brought my muffler to work and cut it open...well, see for yourself. I just hope it doesn't make it too loud now!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 04:31:51 pm
Slashback my muffler has a serious case of the Tweety bird problem...

I'm ordering my Penta pipe as soon as i get my bonus.. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 19, 2007, 04:35:14 pm
Ek het hierdie "tweety bird" met 'n spanner gemoer en sy stert vere uitgepluk met 'n vice-grip...kom ons hoor hoe vluit hy nou...!!!! >:D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 04:45:09 pm
Ek het hierdie "tweety bird" met 'n spanner gemoer en sy stert vere uitgepluk met 'n vice-grip...kom ons hoor hoe vluit hy nou...!!!! >:D

haha lekker man
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on November 19, 2007, 04:52:37 pm
Seems like 10W oil is in order and 1 litre of oil should be enough...

Also looks like i can blow the seals out with compressed air after i removed the oil off coarse ;D

I've just replaced my oil with 10W and would not recommend it. While it gives a better ride on tar it really makes the ride off road too bumpy. I'm going to drain half of it and replace it with 5W.

I used no special tool to remove the seals - simply insert the sliders and yank them out. And repeat. You'll have to loosen the damper bolt though for which you require a special Kawasaki tool or a 24mm nut welded to an approx 48cm long T bar. Don't discard your old seals as they're quite handy to use when fitting your new seals.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 04:57:34 pm
Seems like 10W oil is in order and 1 litre of oil should be enough...

Also looks like i can blow the seals out with compressed air after i removed the oil off coarse ;D

I've just replaced my oil with 10W and would not recommend it. While it gives a better ride on tar it really makes the ride off road too bumpy. I'm going to drain half of it and replace it with 5W.

I used no special tool to remove the seals - simply insert the sliders and yank them out. And repeat. You'll have to loosen the damper bolt though for which you require a special Kawasaki tool or a 24mm nut welded to an approx 48cm long T bar. Don't discard your old seals as they're quite handy to use when fitting your new seals.

Do i need the T bar tool if i want to blow the seal out with compressed air?
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on November 19, 2007, 05:13:00 pm
I'm not sure where the nozzle for the compressor would go as I've not done or seen this procedure before. If I were to hazard a guess I'd say it would probably go into the hole at the bottom of the fork which is where the damper bolt is fastened, in which case you'll probably need it. Have you got a link with some pics/description of how this is done?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 05:18:02 pm
I'm not sure where the nozzle for the compressor would go as I've not done or seen this procedure before. If I were to hazard a guess I'd say it would probably go into the hole at the bottom of the fork which is where the damper bolt is fastened, in which case you'll probably need it. Have you got a link with some pics/description of how this is done?

No all you do is remove the two shocks.

Drain the oil.

Put the shock in a vice.

Remove the circlip holding the seal in place.

Put the drain screw back.

Connect a compressor to the airvalve at the top of the shock.

Behold as the seal pops out.

Put the new seal in and put the circlip back.

Easy as pie...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 05:26:10 pm
Got this from KLR650.net forums

If you've got access to an air compressor, there is no need to disassemble the forks to change the seals. Remove the clip holding the dust seal in, cover the fork seal with a rag, then add air pressure to the fork. 30psi might do it, but one of mine took 130psi.
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on November 19, 2007, 05:49:15 pm
In that case you certainly won't need the T bar. Does it say whether you should drain the forks first?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 05:53:31 pm
In that case you certainly won't need the T bar. Does it say whether you should drain the forks first?

hahaha yes obviously otherwise you're going to be covered from head to toe with oil... ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 19, 2007, 08:18:19 pm
Hi Captain. Neem asseblief n paar photies terwyl jy daai operasie doen, ek sal laaik om te sien.

Tx
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 08:23:06 pm
I will do Uncle

Took the wheel off tonight. Will do the bearings tomorrow.

Will remove the shocks tomorrow afternoon.
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on November 19, 2007, 10:07:24 pm
In that case you certainly won't need the T bar. Does it say whether you should drain the forks first?

hahaha yes obviously otherwise you're going to be covered from head to toe with oil... ;D

Good point, but what's the rag for then?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 19, 2007, 10:08:49 pm
In that case you certainly won't need the T bar. Does it say whether you should drain the forks first?

hahaha yes obviously otherwise you're going to be covered from head to toe with oil... ;D

Good point, but what's the rag for then?

To stop the spray from the little bit of oil left in the shock
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 19, 2007, 10:09:20 pm
In that case you certainly won't need the T bar. Does it say whether you should drain the forks first?

hahaha yes obviously otherwise you're going to be covered from head to toe with oil... ;D

Good point, but what's the rag for then?

It could be your time of the month?
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on November 19, 2007, 10:11:24 pm
 :BangHead: :BangHead: :lol:
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 20, 2007, 01:10:32 pm
Help needed: I can't get the KLRs front wheel bearings out....
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 20, 2007, 04:01:27 pm
I decided not to replace the front wheel bearings. I inspected them. The turn fine. Also took the rubber seals off.. grease looks perfect.. no sign of rust.

When i get home tonight i'll remove the shocks.
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on November 20, 2007, 05:39:57 pm
Now they've been opened, you're going to get water in there. Replace the fcukers. If you sukkel, my old man has a saying: When in doubt, use a hammer, the bigger the doubt, the bigger the hammer.

I saw Shark's rear bearings fail while he was riding. Jy gaan jou gat af val as dit met jou voor wiel gebeur.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 20, 2007, 05:43:03 pm
Now they've been opened, you're going to get water in there. Replace the fcukers. If you sukkel, my old man has a saying: When in doubt, use a hammer, the bigger the doubt, the bigger the hammer.

I saw Shark's rear bearings fail while he was riding. Jy gaan jou gat af val as dit met jou voor wiel gebeur.

Naaa they will not fail...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 20, 2007, 07:35:23 pm
There was a huge oil explosion in my garage a few minutes ago...  :D

I removed the shocks and open the drain plug for some reason the shock was under pressure and it spew oil out that little hole... har har har I'm covered up to my knees in oil.

As i guessed the left hand shock had very little oil in it.  :o
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on November 20, 2007, 07:37:24 pm
haha, must press the valve and release the built up pressure before working on that.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 20, 2007, 07:41:07 pm
haha, must press the valve and release the built up pressure before working on that.


Ja i know that now ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on November 20, 2007, 07:42:46 pm
Bwahahahaha....mooi so Cappie.
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 20, 2007, 07:47:28 pm
haha, must press the valve and release the built up pressure before working on that.


Ja i know that now ;D

Perhaps now is the time for that small rag?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 20, 2007, 07:49:29 pm
haha, must press the valve and release the built up pressure before working on that.


Ja i know that now ;D

Perhaps now is the time for that small rag?


No i like the feeling of fork oil between my toes ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 20, 2007, 07:52:24 pm
ROFL!

Mooi so Cappie!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 20, 2007, 07:55:05 pm
Dankie dankie :grin:

F*k i really got a workout pumping all the oil out of the shocks.. its doesn't run out you have to pump it out..;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 10:02:57 am
The shock boots are in the cleaning process..

Haha yes i'm steam cleaning them ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 12:01:34 pm
Two very clean, as good as new, fork booties.. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 12:31:24 pm
Two steam cleaned shocksies to go with the steam cleaned booties ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 21, 2007, 03:19:55 pm
Ons moet hierdie outjie dophou, hy's sterk op die aftraende pad!

Steamcleaned shocks?

 :o
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 04:42:07 pm
Ons moet hierdie outjie dophou, hy's sterk op die aftraende pad!

Steamcleaned shocks?

 :o


Bhahahaha hoekom?? Moenie worry nie man... ek het hulle nie baie warm gemaak nie... ook koue water gebruik om die seels koud te hou
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 04:47:22 pm
The compressed air worked like a charm....

Just add air to the shocks slowly and tie rags around the seal entrance to stop oil explosions  :D

Seals pop out easily...

No need to take the shocks apart to change the seals.  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 04:48:22 pm
New seal  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 04:50:44 pm
Shocks with new seals and filled with oil... will check the exact oil amounts when the shocks are installed.  ;)

Ready to fit and ride.

I'm proud of this job... looks really nice.  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on November 21, 2007, 06:42:24 pm
Nice one CS!
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 21, 2007, 08:06:42 pm
Good job CS, and thanks for the pics.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 21, 2007, 08:11:24 pm
Its really easy to change those seals.. no special tools needed only a pump ;D

The removing and fitment of the shocks is a different story... especially since i am alone..
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 22, 2007, 05:28:48 pm
Should i replace the fork clamp bolts?? I want to put in high strength alan caps...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 22, 2007, 09:15:45 pm
KLR in surgery  :D
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on November 23, 2007, 02:31:40 pm
Should i replace the fork clamp bolts?? I want to put in high strength alan caps...

The torque spec on those bolts are so low that it would really be a waste - I think it's about 30. If your bolts are rounded because the wrong/cheap sockets were used then do go ahead.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 23, 2007, 02:38:01 pm
Should i replace the fork clamp bolts?? I want to put in high strength alan caps...

The torque spec on those bolts are so low that it would really be a waste - I think it's about 30. If your bolts are rounded because the wrong/cheap sockets were used then do go ahead.

In that case i will just keep my old ones
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 23, 2007, 09:47:02 pm
The KLR is back together and the shock job looks and feels really nice.

My clutch and side stand switch combination is giving me hassles again. Will lube and clean the switches tomorrow but i'll be looking out for a mod to disable both these switches. There is no way i can ride off with the sidestand down.

Another thing. Can i buy a 2008 KLR gear lever and fit it to my KLR... my gear lever is shot and i need one ASAP.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 24, 2007, 08:13:46 am
Captain, thoses switches are for safety, and I don't recommend dissabling them. However if you really still want to, the side stand one is easy. Just unscrew the cover, and pull the cable gently out of it's seated position. I can't remember if the sidestand must be up or down to do this, but just try both, it's easy enough.
Just let the cable hang loose, then you can put the bike in gear with the side stand down.
I had my bike like this for a few days, but I put the cable back, because the KLR has a very loooong side stand, which I think is more dangerous than other bikes if you forget about it.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 24, 2007, 11:23:16 am
Don't worry Uncle i cleaned the clutch switch which was very dirty again.. and now its working perfectly. Will not disable as long as they work.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 25, 2007, 04:20:15 pm
I tested the bike on the road today and yislaaik what a difference those shocks make...

I also noticed the bikes turn-in is a bit slower but more stable... i suppose its because i raised the front a bit. Less head shaking too...

I also found that the front end does not bounce nearly as much as it used to do... seems like the 10W oil is the way to go.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 25, 2007, 04:30:44 pm
Question.
Captain has a 2005 model that he got with 43000 (I think) kilos on the clock, and he says it helped to do the front shocks.

My bike is also a 2005 model, but the person that had it before me had it lying around doing nothing for two years, the bike has now only got 4500 Kilos on.

Do I need to do my front shocks?

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 25, 2007, 04:34:49 pm
Hy het nou al 52000km op
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 25, 2007, 04:37:29 pm
Uncle remeber i did my shocks because my one seal was busted... i only put the 10W oil in on recomedation... but it seems to be worth it...


Also you don't have to "do" your shocks.... ;D Just change the oil... easy job... just drain and refill..
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 26, 2007, 01:16:33 pm
I ordered my new Penta exhaust pipe ;D
Title: Re: KLR650 Restoration....Please help......
Post by: 1X on November 26, 2007, 02:21:36 pm
Full system or just slip on?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 26, 2007, 02:28:39 pm
Full system or just slip on?

Slipon
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 26, 2007, 05:21:31 pm
I'm busy building myself a luggage plate and two tool tubes... its going to work lekker... just have to move the rear indicators ;D

I'll post pics when i make more progress... 
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 27, 2007, 02:17:08 pm
Work in progress ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 27, 2007, 09:01:24 pm
Captain, that thing looks like it's going to be seriously heavy, even for aluminium! It does, however, look like THE business!
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 27, 2007, 09:16:17 pm
Captain, that thing looks like it's going to be seriously heavy, even for aluminium! It does, however, look like THE business!

Looks just right...

Life is either
A daring adventure
Or nothing
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 28, 2007, 07:01:38 am
Captain, that thing looks like it's going to be seriously heavy, even for aluminium! It does, however, look like THE business!

Looks just right...

Life is either
A daring adventure
Or nothing


Thanks...  ;)

Uncle the measurements are 500 x 300 x 4.5... its not that heavy... i'm sure weighs less than my empty topbox..

The idea arount that plate is to remove the topbox, install the plate, then fit my tool tube and tyre inflator to it, tie my matress, sleeping bag and tent on top of the plate and soft panniers for clothes... ready to take on the road...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 28, 2007, 05:21:20 pm
Plate job is making progress...  ;D

Perfect size...

The slots on the sides still needs to be cut..

I'm also going to cut a hole to access the top tool storage..  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 28, 2007, 07:59:27 pm
Tested the plate on the bike... and it vibrates alot at 120... I think some foam rubber would fix the problem.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 28, 2007, 08:05:13 pm
Hi Captain
There's a strip of foam rubber that you seal doors with, they sell it at places like builders warehouse. This stuff has got glue on one side, and it's sold in different sizes, ie how thick and broad it is. I bought some about a year ago, and it was quite cheap, and I've used it for a lot of stuff other than just that door.

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 28, 2007, 08:09:49 pm
Hi Captain
There's a strip of foam rubber that you seal doors with, they sell it at places like builders warehouse. This stuff has got glue on one side, and it's sold in different sizes, ie how thick and broad it is. I bought some about a year ago, and it was quite cheap, and I've used it for a lot of stuff other than just that door.



Thanks Unlce i've got a big roll of the stuff at work.. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 28, 2007, 08:20:39 pm
Hi Captain
There's a strip of foam rubber that you seal doors with, they sell it at places like builders warehouse. This stuff has got glue on one side, and it's sold in different sizes, ie how thick and broad it is. I bought some about a year ago, and it was quite cheap, and I've used it for a lot of stuff other than just that door.



Hehehe, I've used that stuff all over on my bike! I took the seat and tank off and laid that shit EVERYWHERE!! Squeaks and rattles...HAH ! No more!
Title: Re: KLR650 Restoration....Please help......
Post by: IDR on November 28, 2007, 09:03:27 pm
Hi Captain
There's a strip of foam rubber that you seal doors with, they sell it at places like builders warehouse. This stuff has got glue on one side, and it's sold in different sizes, ie how thick and broad it is. I bought some about a year ago, and it was quite cheap, and I've used it for a lot of stuff other than just that door.



Hehehe, I've used that stuff all over on my bike! I took the seat and tank off and laid that shit EVERYWHERE!! Squeaks and rattles...HAH ! No more!

Where would one go to buy some of it, I need to cover my Z, finally get rid of the Dog-forsaken F$@#%$@#%$#KING fairing buzz...
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on November 28, 2007, 09:06:27 pm
Hi Captain
There's a strip of foam rubber that you seal doors with, they sell it at places like builders warehouse. This stuff has got glue on one side, and it's sold in different sizes, ie how thick and broad it is. I bought some about a year ago, and it was quite cheap, and I've used it for a lot of stuff other than just that door.



Hehehe, I've used that stuff all over on my bike! I took the seat and tank off and laid that shit EVERYWHERE!! Squeaks and rattles...HAH ! No more!

Where would one go to buy some of it, I need to cover my Z, finally get rid of the Dog-forsaken F$@#%$@#%$#KING fairing buzz...

Thats a fly in your ear, not the fairing...
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on November 28, 2007, 09:09:39 pm
IDR, just check at Builders warehouse or similar, it's widely available at hardware stores.
Title: Re: KLR650 Restoration....Please help......
Post by: buzzlightyear on November 28, 2007, 09:29:05 pm
Where would one go to buy some of it, I need to cover my Z, finally get rid of the Dog-forsaken F$@#%$@#%$#KING fairing buzz...

Try these guys: http://www.proautorubber.co.za/. I bought new doorseals for the car from them yesterday, and saw that they have rolls of those foam strips with the glue strip on the one side. They probably supply the retailers, their prices are good.

You are looking for these: http://www.proautorubber.co.za/sponge.htm

I see they are in Boksburg for the Gauties
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on November 30, 2007, 10:27:33 am
Hi Captain
There's a strip of foam rubber that you seal doors with, they sell it at places like builders warehouse. This stuff has got glue on one side, and it's sold in different sizes, ie how thick and broad it is. I bought some about a year ago, and it was quite cheap, and I've used it for a lot of stuff other than just that door.



Hehehe, I've used that stuff all over on my bike! I took the seat and tank off and laid that shit EVERYWHERE!! Squeaks and rattles...HAH ! No more!

Where would one go to buy some of it, I need to cover my Z, finally get rid of the Dog-forsaken F$@#%$@#%$#KING fairing buzz...

This should actually go in the Pooratech fred: I sorted all my KLR's rattles out in one cheap purchase.......earplugs!
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 30, 2007, 10:39:50 am
Hi Captain
There's a strip of foam rubber that you seal doors with, they sell it at places like builders warehouse. This stuff has got glue on one side, and it's sold in different sizes, ie how thick and broad it is. I bought some about a year ago, and it was quite cheap, and I've used it for a lot of stuff other than just that door.



This system also works extremely well when it time to do the dishes/change nappies/ mow the lawn etc etc ;) ;)

Hehehe, I've used that stuff all over on my bike! I took the seat and tank off and laid that shit EVERYWHERE!! Squeaks and rattles...HAH ! No more!

Where would one go to buy some of it, I need to cover my Z, finally get rid of the Dog-forsaken F$@#%$@#%$#KING fairing buzz...

This should actually go in the Pooratech fred: I sorted all my KLR's rattles out in one cheap purchase.......earplugs!

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 30, 2007, 12:35:01 pm
Groenie i'll post it in Pooratech when it is finished.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 30, 2007, 12:35:44 pm
Got the material for the two tool tubes...

Cost me a full R36 ;D
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on November 30, 2007, 12:51:34 pm
Oops, dunno what happened to previous post!! It deleted my comment!
I said that the ear-plug "fix" also gets rid of irritating noises like ...
"Mow the lawn!"
"Change the nappy!"
"Wash those dishes!"
"You are NOT going riding with that bunch of mis-fits again!"

 ;) ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 30, 2007, 01:08:35 pm
Oops, dunno what happened to previous post!! It deleted my comment!
I said that the ear-plug "fix" also gets rid of irritating noises like ...
"Mow the lawn!"
"Change the nappy!"
"Wash those dishes!"
"You are NOT going riding with that bunch of mis-fits again!"

 ;) ;)

bhahahaha i never get those noises anyway...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on November 30, 2007, 05:32:07 pm
Plate and tool tubes finished...

The tool tubes may need to be made shorter.... will see when it is on the bike.. ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 01, 2007, 02:41:00 pm
Today i replace the KLRs water pump gasket which i tore last time when i did the clutch. Also drained the coolend and put some better coolant in the bike.

Green KLR piepie  :D Expensive at R35 per liter...  :D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 01, 2007, 02:43:14 pm
Also replaced the clutch side gasket which i also destroyed last time i did the clutch...  ;D

Torqued the clutch bolts...  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: Kev on December 02, 2007, 12:34:59 am

Green KLR piepie  :D Expensive at R35 per liter...  :D

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=5474.0;attach=7243;image)


Just a warning: Antifreeze / coolant is DEADLY for dogs... and for some reason, they love it. Apparantly it tastes sweet to them. Just a few licks is enough to puppy very very ill indeed.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 02, 2007, 08:54:57 am
Luckily i live in a complex where no dogs is allowed ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 02, 2007, 08:56:11 am
Damn i cant wait for my Penta to arrive.... Tweety is driving me crazy...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 03, 2007, 03:27:50 pm
My Christmas pressie arrived and just like Michnus said the quality of the product is excellent..  ;D

Can't wait to fit.
Title: Re: KLR650 Restoration....Please help......
Post by: Meerkat on December 03, 2007, 04:19:55 pm
OOOOOOOOOOHHHHHHHHHHHHHHHHHHHHHH,  that is REAL pretty!!!!!
Title: Re: KLR650 Restoration....Please help......
Post by: Thunderlinde on December 03, 2007, 04:58:32 pm
OOOOOOOOOOHHHHHHHHHHHHHHHHHHHHHH,  that is REAL pretty!!!!!
Gaan jy vir jou ook n ander een opsit?
Title: Re: KLR650 Restoration....Please help......
Post by: AdventureBoy on December 03, 2007, 05:08:42 pm
Hi Captain
I have just recently fitted a Penta to my KLR. Very happy with the sound and it smoothed my bike out nicely. She really feels more responsive. When fitting look out for the side cover. I have just returned from a long ride and have a hole burnt in the sidecover. The exhaust allows a lot of adjustment on the fromt end. Use it to position the pipe away from the cover. Also use locktite and ny-lock nuts. On my first short ride I arrived home with both nuts missing and the pipe hanging on the header.
Best of luck
AdventureBoy
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 03, 2007, 05:11:57 pm
Hi Captain
I have just recently fitted a Penta to my KLR. Very happy with the sound and it smoothed my bike out nicely. She really feels more responsive. When fitting look out for the side cover. I have just returned from a long ride and have a hole burnt in the sidecover. The exhaust allows a lot of adjustment on the fromt end. Use it to position the pipe away from the cover. Also use locktite and ny-lock nuts. On my first short ride I arrived home with both nuts missing and the pipe hanging on the header.
Best of luck
AdventureBoy

I will use loctite... thanks for the heads up ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 03, 2007, 07:21:01 pm
I am very happy....

Geezzz i love the pipe...

Beautiful sound... it sounds like a proper big 4 stroke..  ;D

It revs super fast...

I was actually shaking when i got off the bike...

Still needs to be adjusted to get the side cover on.. got to dark.. could not take a picture.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on December 03, 2007, 07:45:52 pm
Nice Captain - Lyk darem stukke beter as die original ne?
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on December 03, 2007, 07:51:00 pm

I will use loctite... thanks for the heads up ;D
27 pages and you finally grasp the first rule!
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on December 03, 2007, 08:34:59 pm
  ;D  ;D  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on December 03, 2007, 09:07:26 pm

27 pages and you finally grasp the first rule!


Cappie is a professional student. It sometimes takes them their whole lives to learn something...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 03, 2007, 09:12:27 pm

I will use loctite... thanks for the heads up ;D
27 pages and you finally grasp the first rule!


Nono i've been using the holy stuff all the time ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 03, 2007, 09:13:16 pm

27 pages and you finally grasp the first rule!


Cappie is a professional student. It sometimes takes them their whole lives to learn something...

Wel my naam is Captain Slow ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 03, 2007, 09:14:21 pm
Nice Captain - Lyk darem stukke beter as die original ne?

Uncle as jy dink die pyp lyk mooi dan moet jy hoor hoe klink die ding... dammit man dis klink soos kuns.. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on December 03, 2007, 09:42:28 pm
Ek het jou mos gesê hy klink baie beter as die Powerflow.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 06:54:33 am
Here it is mounted...

Still needs some adjustment to get the side cover back on..  :P
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on December 04, 2007, 08:52:46 am
Thats real purty Cappy!! Well done!!
Title: Re: KLR650 Restoration....Please help......
Post by: Meerkat on December 04, 2007, 10:42:51 am
OOOOOOOOOOHHHHHHHHHHHHHHHHHHHHHH,  that is REAL pretty!!!!!
Gaan jy vir jou ook n ander een opsit?


Tempted, baie tempted.....
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 10:52:44 am
Guys the old pipe is dead weight...

You'll feel immediately after you installed the Penta pipe the engine sound happy and free... then when you twist the throttle and look at the rev counter you'll see it revs way faster almost like a racing bike...

and the sound is excellent so is the looks...


I rode to work this morning and i creeped up behing this lady walking her dog... i selected a lower gear and wacked the throttle open... you should have seen the fright she got.... bhahahahaha evil me..
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on December 04, 2007, 11:22:13 am
Guys the old pipe is dead weight...

You'll feel immediately after you installed the Penta pipe the engine sound happy and free... then when you twist the throttle and look at the rev counter you'll see it revs way faster almost like a racing bike...

and the sound is excellent so is the looks...


I rode to work this morning and i creeped up behing this lady walking her dog... i selected a lower gear and wacked the throttle open... you should have seen the fright she got.... bhahahahaha evil me..

If you make an air leak at the cylinder head connection it also backfires every time you shut off!!!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 11:34:11 am
Guys the old pipe is dead weight...

You'll feel immediately after you installed the Penta pipe the engine sound happy and free... then when you twist the throttle and look at the rev counter you'll see it revs way faster almost like a racing bike...

and the sound is excellent so is the looks...


I rode to work this morning and i creeped up behing this lady walking her dog... i selected a lower gear and wacked the throttle open... you should have seen the fright she got.... bhahahahaha evil me..

If you make an air leak at the cylinder head connection it also backfires every time you shut off!!!

haha i don't want to draw that much attention ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 05:46:37 pm
Guys i need advice...

I installed the new pipe as you all know...

The bike is running fine... idling is fine... no backfiring... It starts fine... everything is lekker...

Do i really have to set the air screw and shim the needle... since i got that incredible fuel economy figure last weekend i don't really want to fiddle with the carb... its a case of "Its not broken so don't F**k with it"
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on December 04, 2007, 06:06:24 pm
Guys i need advice...

I installed the new pipe as you all know...

The bike is running fine... idling is fine... no backfiring... It starts fine... everything is lekker...

Do i really have to set the air screw and shim the needle... since i got that incredible fuel economy figure last weekend i don't really want to fiddle with the carb... its a case of "Its not broken so don't F**k with it"

You do understand that you do not have the willpower not to fiddle with it don,t you ::) ::) ::)

But I do trust this will worry you all night????
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on December 04, 2007, 07:16:44 pm
Captain, I agree with the don't fix it if it aint broken thing. You don't have to do EVERY mod in the book. Unless of course you want to. In that case take advice from Welsh and lie awake worrying about it tonight. If you're doing the job by 5 tomorrow morning, it just had to be done.
 >:D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 07:36:12 pm
Dammit guys you are not much of a help ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 07:36:40 pm
I think i need a girlfriend ;D
Title: Re: KLR650 Restoration....Please help......
Post by: NISMARK on December 04, 2007, 07:37:53 pm
I think i need a girlfriend ;D

To help work on the KLR?! :D

Good luck
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 07:39:17 pm
I think i need a girlfriend ;D

To help work on the KLR?! :D

Good luck

Ek het nog altyd 'n girl gesoek wat ek kan vuilsmeer en dan .... :)
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on December 04, 2007, 07:41:11 pm
K@K

Jy soek net iets om met daai blik ghries te doen wat jy gekoop het!

 ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 07:45:26 pm
K@K

Jy soek net iets om met daai blik ghries te doen wat jy gekoop het!

 ;D


Jislaaik ou maat... min dinge so mooi soos 'n well oiled woman ;D
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on December 04, 2007, 07:50:24 pm
Pasop net dat die dip-stick nie uitval nie!!! ;) ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 07:52:44 pm
My dipstick het darem nog nie probleme nie ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on December 04, 2007, 07:53:26 pm
En onthou jou ATGATT.
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on December 04, 2007, 07:55:08 pm
Very sharp Uncle!!!! 8)
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on December 04, 2007, 07:56:13 pm
En onthou jou ATGATT.

Reen-jas?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 04, 2007, 07:57:06 pm
En onthou jou ATGATT.

Let those who ride decide ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 06, 2007, 07:08:34 am
I found another good reason for fitting the Penta pipe... Those flippen Pedestrians can finally hear me coming...

This morning one attemted to walk infront of me ... one little rev and all eyes were on me. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 07, 2007, 05:17:46 pm
I continued work on the luggage plate should be finished next week.

Pic1: Foam rubber to stop the vibration noise

Pic2: Fitted to the bike without the top box bracket. When i have my soft pannier this is how i will use the plate.

Pic3: Fitted with the top box bracket

Still working on fitting the tool tubes. I actually have to move the indicators but i have no time. Will do that next year.  ;)


Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 08, 2007, 06:18:19 pm
Got my pannier bags and also a waterproof bag to put all my camping equipment in..
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on December 08, 2007, 06:23:29 pm
Nice so far.
Am I seeing right that you did a small cut - out on the plastics to make the zorst fit?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 08, 2007, 06:29:02 pm
Nice so far.
Am I seeing right that you did a small cut - out on the plastics to make the zorst fit?

Haha no that was the previous owner.... he probably had one fitted too... funny enough i only noticed the plastic was cut out when i put the cover back this afternoon.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 08, 2007, 06:30:23 pm
Those bags are the bizniz i love em...
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 10, 2007, 12:36:54 pm
Got my gear lever today  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on December 11, 2007, 08:49:54 am
The KL650C (2007 KL650A) lever and the one you got (2008KLR) are mechanically identical although not exactly the same and they have different part numbers. The earlier one is spray painted in silver matching the colour of the frame. The 2008 lever is galvanised (cheaper).
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 11, 2007, 09:00:49 am
Le Cap the lever i bought is the 2008 lever but its very shiny almost looks like stainless... doesn't look like any galvanizing i've seen before
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on December 11, 2007, 03:31:25 pm
Nice so far.
Am I seeing right that you did a small cut - out on the plastics to make the zorst fit?

Haha no that was the previous owner.... he probably had one fitted too... funny enough i only noticed the plastic was cut out when i put the cover back this afternoon.
I'm starting to like the Penta... contact details anyone?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 11, 2007, 03:34:14 pm
Nice so far.
Am I seeing right that you did a small cut - out on the plastics to make the zorst fit?

Haha no that was the previous owner.... he probably had one fitted too... funny enough i only noticed the plastic was cut out when i put the cover back this afternoon.
I'm starting to like the Penta... contact details anyone?

www.pentaperformance.co.za
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on December 11, 2007, 07:32:05 pm
Captain, if you had to guess, how much better do you think that 08 gear lever will hold up compared to the original if you drop the bike? And is the welding on the new lever better than on the old?

Tx
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 11, 2007, 09:19:38 pm
Captain, if you had to guess, how much better do you think that 08 gear lever will hold up compared to the original if you drop the bike? And is the welding on the new lever better than on the old?

Tx

The new lever is way better the old one is a piece of Kawasaki sh*t just like the doo...  Short and sweet my 2c
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 11, 2007, 09:21:48 pm
I never would have guessed how addictive modding the KLR would be... i find myself ordering stuff all the time ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Eisbein on December 11, 2007, 11:19:16 pm
I never would have guessed how addictive modding the KLR would be... i find myself ordering stuff all the time ;D

What ?

No way!

29 pages later and you're still going !
You've been in Groenie's company a little too long ...


Lekker!


:D ;D

At least all your mods are functional.

Keep it coming...

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 12, 2007, 07:02:40 am
My bike almost runs as well as Groenie's still needs the carb mods but i think i'm going to skip those...
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on December 12, 2007, 07:38:41 am
I never would have guessed how addictive modding the KLR would be... i find myself ordering stuff all the time ;D

You need a girlfriend!!!
Title: Re: KLR650 Restoration....Please help......
Post by: MrBig on December 12, 2007, 08:19:35 am
I really enjoy this thread thanks Captain
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 12, 2007, 08:56:37 am
I never would have guessed how addictive modding the KLR would be... i find myself ordering stuff all the time ;D

You need a girlfriend!!!

lol
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 12, 2007, 08:57:11 am
I really enjoy this thread thanks Captain

My pleasure glad someone is reading it ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Stofstreep on December 12, 2007, 09:32:56 am
I really enjoy this thread thanks Captain

My pleasure glad someone is reading it ;D

Duh!!!

;D ;D
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on December 14, 2007, 03:27:34 pm
I never would have guessed how addictive modding the KLR would be... i find myself ordering stuff all the time ;D
Well you have me doing it now as well! Just ordered a Penta. :-)
Keep posting the things you do Captain, this is turning into a manual!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 14, 2007, 03:37:39 pm
I never would have guessed how addictive modding the KLR would be... i find myself ordering stuff all the time ;D
Well you have me doing it now as well! Just ordered a Penta. :-)
Keep posting the things you do Captain, this is turning into a manual!

Ya i'm gonna cry if this thread gets lost some day.

You gonna love that Penta... very good quality and it sounds great...
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on December 14, 2007, 04:02:18 pm
I never would have guessed how addictive modding the KLR would be... i find myself ordering stuff all the time ;D
Well you have me doing it now as well! Just ordered a Penta. :-)
Keep posting the things you do Captain, this is turning into a manual!

Ya i'm gonna cry if this thread gets lost some day.

You gonna love that Penta... very good quality and it sounds great...
Yeah... let's see how it grows and maybe mirror it somewhere... Call it Cap'n Slows KLR workshop. :-)
Title: Re: KLR650 Restoration....Please help......
Post by: shark_za on December 16, 2007, 09:38:19 am
btw, if you break your side covers or loose them, be prepared to shell out R400 bucks a pop.
Same with the small crack in my windshield, also R400 for a new one.

The KLR is now getting red again.

I'll give you a proper report on the dyno thing, taking it to Freez sometime, as soon as I have some spare cash and the Uni Air filter I plan on using.

I'm starting to love the bike again, ooops.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 16, 2007, 01:53:55 pm
I love mine too ;D
Title: Re: KLR650 Restoration....Please help......
Post by: sidetrack on December 17, 2007, 06:02:00 pm
btw, if you break your side covers or loose them, be prepared to shell out R400 bucks a pop.
Same with the small crack in my windshield, also R400 for a new one.

The KLR is now getting red again.

I'll give you a proper report on the dyno thing, taking it to Freez sometime, as soon as I have some spare cash and the Uni Air filter I plan on using.

I'm starting to love the bike again, ooops.


So you are not selling anymore ?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on December 24, 2007, 12:15:11 pm
So i forgot my pump at home in PE....

Off to the bicycle shop this morning....

I asked the oom behind the counter... "Oom i need a good pomp for the motorcycle wheel, ek willie te veel sweet nie" ;D

So he sold me this beautiful little pump. It has a piece so you can step on it to keep it on the ground and i tested it. It pumps a bike wheel quick quick.

So there i go off to the hardware store to get some bolts and nuts to make a permanent bracket.

It think i really did a good job. ;)
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on December 24, 2007, 01:53:08 pm
Quote from: CAPTAIN SLOW
So there i go off to the hardware store to get some bolts and nuts to make a permanent bracket.

It think i really did a good job. ;)

Very neat Cap'n!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 14, 2008, 04:22:06 pm
My Aerotrim screen broke off on Saturday as i was cruising on the highway, seems like i'll have to make some metal brackets for it.

Haha funny enough i only noticed how much the Aerotrim helped when i fell off at speed. It takes alot of wind blast away from the helmet. When it fell off i could feel the extra strain on my neck from the wind.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 14, 2008, 04:24:22 pm
I decided to finally remove the clutch and sidestand switches. Yes i know some people don't agree but it seems to be the only thing on the bike that keeps on letting me down.

I did 2500km in three weeks and those switches seriously f*cked around.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 14, 2008, 08:50:27 pm
Kom kom kom, jy's supposed om pics by te sit. Especially the clutch one, my bike died at a robot today and I sweated like a pig to get it started again, it just would not pick up the fact that I was in neutral and so it wouldn't start.
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on January 14, 2008, 10:20:36 pm
Mine would often not start if I have the clutch pulled in. Is this a symptom of a problematic clutch switch?
Title: Re: KLR650 Restoration....Please help......
Post by: slashback on January 14, 2008, 10:22:48 pm
Yep, I went for a ride with JonW and his was doing the same thing, try pulling your clutch lever in as hard as you can, if it works, then your switch is going ta-ta
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 14, 2008, 10:24:00 pm
Lootch, mine won't start at all if the clutch is pulled in. I know there's a couple of mods that a person can do, but I need time to read them.
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on January 14, 2008, 10:47:08 pm
Lootch, mine won't start at all if the clutch is pulled in. I know there's a couple of mods that a person can do, but I need time to read them.
Mmmmm idiot switches, I learned to ride on a CB360, it had none of these fancy cut out switches exept the engine cutout. Methinks we have lawyers to blame for all this extra stuff that can break...
Title: Re: KLR650 Restoration....Please help......
Post by: sidetrack on January 14, 2008, 11:48:59 pm
The sidestand switch I can still understand but the clutch switch ? What is the worst that can happen, you hit the starter in gear and the bike jumps a massive 30 cm ?
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on January 15, 2008, 11:03:27 am
I need to remove mine as well. I'm used to pulling in the clutch when I start the bike, just a habit. But lately it sometimes works and sometimes doesn't. Not much of a hassle at the moment, but I'm sure it's going to give me kark soon.

So, is this the topic for the next tech day?
Title: Re: KLR650 Restoration....Please help......
Post by: IDR on January 15, 2008, 11:06:57 am
On the 08 KLR, it has to be in neutral to start, clutch in or not, side stand out or not... drives me up the wall.  Start it, get on, kick into gear, stall.... kick into neutral, start over.  Yea yea, don't stall it, but still, it's making my nads sag.
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on January 15, 2008, 11:08:39 am
That becomes a problem when you're stuck in a tricky section....maybe there's a way around it?
Title: Re: KLR650 Restoration....Please help......
Post by: IDR on January 15, 2008, 11:15:38 am
That becomes a problem when you're stuck in a tricky section....maybe there's a way around it?
Maybe... I hope so - I'll be first in line!
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on January 15, 2008, 12:42:46 pm
And here we go, with thanx to our chommas at KLRWorld.com - http://klrworld.com/forums/index.php/topic,1723.0.html (http://klrworld.com/forums/index.php/topic,1723.0.html)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 15, 2008, 08:41:34 pm
I will be removing mine this weekend. Will take pics.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 16, 2008, 06:34:43 pm
Pic as promised.

Cut the wire shown. Solder the two wire at the top and cover with tape.  ;)
Title: Re: KLR650 Restoration....Please help......
Post by: Jules on January 16, 2008, 07:33:59 pm
On the 08 KLR, it has to be in neutral to start, clutch in or not, side stand out or not... drives me up the wall.  Start it, get on, kick into gear, stall.... kick into neutral, start over.  Yea yea, don't stall it, but still, it's making my nads sag.

Are you sure?  Both our 08's start fine in gear as long as the clutch is in and the stand is up. Maybe there is a fault on yours somewhere. Doing some technical riding and stalling could be a disaster if you cant quickly fire it up and keep going.


Jules
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 17, 2008, 12:28:50 pm
On the 08 KLR, it has to be in neutral to start, clutch in or not, side stand out or not... drives me up the wall.  Start it, get on, kick into gear, stall.... kick into neutral, start over.  Yea yea, don't stall it, but still, it's making my nads sag.

Are you sure?  Both our 08's start fine in gear as long as the clutch is in and the stand is up. Maybe there is a fault on yours somewhere. Doing some technical riding and stalling could be a disaster if you cant quickly fire it up and keep going.


Jules

Jip sounds like that clutch switch is faulty already ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 18, 2008, 05:15:06 pm
I love my KLR.... ;D

I have been riding with a broken choke lever for a long time. This afternoon i could not take it anymore. So off i went to Kawa to order one.

The salesman says sir that would be R450 for the lever. I go WTF!! He goes nah i'm joking its R70... :laughing4:
Title: Re: KLR650 Restoration....Please help......
Post by: IceCreamMan on January 18, 2008, 05:32:54 pm
On the 08 KLR, it has to be in neutral to start, clutch in or not, side stand out or not... drives me up the wall.  Start it, get on, kick into gear, stall.... kick into neutral, start over.  Yea yea, don't stall it, but still, it's making my nads sag.

how u gonna push start it ?
Title: Re: KLR650 Restoration....Please help......
Post by: Jules on January 19, 2008, 09:10:48 am
On the 08 KLR, it has to be in neutral to start, clutch in or not, side stand out or not... drives me up the wall.  Start it, get on, kick into gear, stall.... kick into neutral, start over.  Yea yea, don't stall it, but still, it's making my nads sag.

how u gonna push start it ?

Good point! Can you push start a KLR with all the safty features in place?

Jules
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 19, 2008, 09:18:25 am
On the 08 KLR, it has to be in neutral to start, clutch in or not, side stand out or not... drives me up the wall.  Start it, get on, kick into gear, stall.... kick into neutral, start over.  Yea yea, don't stall it, but still, it's making my nads sag.

how u gonna push start it ?

Good point! Can you push start a KLR with all the safty features in place?

Jules

Yes you can.... assuming all the switches are working as they should.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 19, 2008, 09:30:34 am
Maybe i should explain the KLR safety switches.

I studied my Clymer KLR wiring diagrams so i know.  ;D

There are 3 switches:

Side stand switch
Clutch switch
Neutral switch

The first circuit is the starting safety circuit. This circuit checks whether it is safe to turn the starter motor without hurting the rider. This circuit makes use of the Neutral and Clutch swithes. It is an "or" operation. In other words for the starter motor to turn you must either have the bike in Neutral "or" you must pull on the Clutch. It this is not done the starter relay will not engage and nothing will happen when you press the happy button.  ;D This circuit becomes faulty on most KLRs and you will usually see the rider moving the clutch lever in and out a bit to get the starter motor to turn. Mine does this and usually cleaning the clutch switch works.

The second circuit is the riding safety circuit. This circuit checks whether the side stand is in the up position when the bike is in gear. If the bike senses the stand is down while the motor is in gear it will immediately cut the motor. This is quite irritating and worrying when this switch goes faulty. It feels almost like the motor is starving of fuel. Meanwhile its the bloody side stand switch indecating a false "stand down" event.

Hope this helps.   
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 19, 2008, 10:34:50 pm
Captain, het jy al die clutch switch ge bypass? Ek wil dit asap doen, dit maak my mal as ek die bike stall in verkeer en ek moet neutral soek. Maar my vraag is, sal die bike start as hy in gear is en ek die clutch intrek?
Title: Re: KLR650 Restoration....Please help......
Post by: IDR on January 19, 2008, 10:45:10 pm
on the '08 - the starter motor will not turn if the bike is onot in neutral - ie. it's fine to run start - but the happy button will not be of any use while in gear.  And yes, I've tried, in gear, stand out and various combinations, if the bike isn't in neutral, it just won't start...
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 19, 2008, 10:54:35 pm
Thanks IDR. That's what I'm trying to figure out. The link that Groenie posted shows a bypass to the starter relay switch. I'm trying to figure out if the bike will start if I do that mod.

Maybe the only way to find out is to do the mod. Normally I wouldn't bypass a safety switch, but the other day for some reason the neutral light wouldn't come on even though the bike was in neutral, and the bike wouldn't start. I need to get that sorted out before I take the bike offroad again, or I might get stuck somewhere bad with a bike that doesn't want to start.

CS, sorry about this huge hijack on your thread!  >:D

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 20, 2008, 11:05:59 am
No problem Uncle this thread is there for all KLR owners ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 20, 2008, 11:07:44 am
on the '08 - the starter motor will not turn if the bike is onot in neutral - ie. it's fine to run start - but the happy button will not be of any use while in gear.  And yes, I've tried, in gear, stand out and various combinations, if the bike isn't in neutral, it just won't start...

ISDR have you checked on other 2008s because i think you have a faulty clutch switch allready. ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 20, 2008, 11:15:51 am
Captain, het jy al die clutch switch ge bypass? Ek wil dit asap doen, dit maak my mal as ek die bike stall in verkeer en ek moet neutral soek. Maar my vraag is, sal die bike start as hy in gear is en ek die clutch intrek?

Uncle have you cleaned the switch yet? You will find it underneath the clutch lever. Two little screws will take it apart. Clean it with a rag and put it back together. This usually works for me.

No i haven't done my clutch switch yet but i will in the future.

It is easy to bypass. There are 3 wire connected to the switch. Use a soldering iron to unsolder them from the switch. Now solder all 3 wires together and cover with tape or heat shrink. Make a note of where the wires came from in case you wanna put them back. ;D

Before you do the mod, first clean the switch. ;)

After the mod it will start if in gear and the clutch in. But it will also start with the bike in gear and the clutch out so watch out!! ;D
Title: Re: KLR650 Restoration....Please help......
Post by: IDR on January 20, 2008, 11:17:42 am
No, I haven't... but then the clutch switch came faulty from the factory - it's been like this since km 0.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 20, 2008, 11:18:45 am
Thanks IDR. That's what I'm trying to figure out. The link that Groenie posted shows a bypass to the starter relay switch. I'm trying to figure out if the bike will start if I do that mod.

Maybe the only way to find out is to do the mod. Normally I wouldn't bypass a safety switch, but the other day for some reason the neutral light wouldn't come on even though the bike was in neutral, and the bike wouldn't start. I need to get that sorted out before I take the bike offroad again, or I might get stuck somewhere bad with a bike that doesn't want to start.

CS, sorry about this huge hijack on your thread!  >:D



Uncle you could always do a running start when that happens ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 20, 2008, 11:19:57 am
No, I haven't... but then the clutch switch came faulty from the factory - it's been like this since km 0.

Boet its a KLR, it comes with lots of faults from the factory. I'll find some-one with an 08 and test it.
Title: Re: KLR650 Restoration....Please help......
Post by: IDR on January 20, 2008, 11:55:00 am
I really need to spend some time and money on the thing though - but it'll have to wait for the December over-spend to be rectified  ;D

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 20, 2008, 12:00:15 pm
I really need to spend some time and money on the thing though - but it'll have to wait for the December over-spend to be rectified  ;D



:laughing4: same here thats why i'm sitting at home and not riding the Baviaans with my friends.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 20, 2008, 01:11:13 pm
I really need to spend some time and money on the thing though - but it'll have to wait for the December over-spend to be rectified  ;D



:laughing4: same here thats why i'm sitting at home and not riding the Baviaans with my friends.

Me too. Thats why we ride KLR's and not GS's.  ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 20, 2008, 01:13:10 pm
I love my KLR ;D
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on January 21, 2008, 09:23:01 am
No, I haven't... but then the clutch switch came faulty from the factory - it's been like this since km 0.

It didn't come faulty! The bozo who assembled your bike did not know how to set the switch. Bet he also overtightened your steering head!

You can slide the switch a little forward and backward if you loosen the bolts a bit. This usually serves to adjust the point where the switch contact closes.
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on January 21, 2008, 09:59:03 am
No, I haven't... but then the clutch switch came faulty from the factory - it's been like this since km 0.

It didn't come faulty! The bozo who assembled your bike did not know how to set the switch. Bet he also overtightened your steering head!

You can slide the switch a little forward and backward if you loosen the bolts a bit. This usually serves to adjust the point where the switch contact closes.
If I ever buy another new bike I want it delivered in the box... so I can check everything! :-)
Or take it to you... :-)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 25, 2008, 10:55:13 pm
Fitted a new choke lever today.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 26, 2008, 01:52:44 pm
Just curious Captain, how did you break yours?
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on January 26, 2008, 02:50:13 pm
Just curious Captain, how did you break yours?

Probably brute force and ignorance ::) ::)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 26, 2008, 04:37:17 pm
Nope it was broken all the time. Previous owner did it.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 27, 2008, 02:57:37 pm
Serviced the bike today ;D

55000km and going strong.
Title: Re: KLR650 Restoration....Please help......
Post by: GreenMachine on January 27, 2008, 10:18:12 pm
No, I haven't... but then the clutch switch came faulty from the factory - it's been like this since km 0.

Here is some discussion on the Clutch switch at KLRworld.com http://klrworld.com/forums/index.php?topic=4948.0;highlight=clutch+switch

And here is the full mod in detail with pictures http://klrworld.com/forums/index.php/topic,1723.0.html

I don't have the 08 but a friend does. He has stalled his bike many times and I have never seen him search for neutral to get it fired back up again.

IMHO it would be a serious issue if you can not engage the start while trail riding.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 27, 2008, 10:23:33 pm
I did the clutch switch mod today, and have a little warning concerning the wet clutch. If the bike is cold and you start the bike while holding the clutch in, it will try to kick forward in the same way it does if you put it into first after starting it. Be aware of that.

Other than that it seems fine.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 28, 2008, 07:20:02 am
I did the clutch switch mod today, and have a little warning concerning the wet clutch. If the bike is cold and you start the bike while holding the clutch in, it will try to kick forward in the same way it does if you put it into first after starting it. Be aware of that.

Other than that it seems fine.

Pasop Uncle jy lê nou weer oppie grond.. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 28, 2008, 07:27:30 pm
I did the clutch switch mod today, and have a little warning concerning the wet clutch. If the bike is cold and you start the bike while holding the clutch in, it will try to kick forward in the same way it does if you put it into first after starting it. Be aware of that.

Other than that it seems fine.

Pasop Uncle jy lê nou weer oppie grond.. ;D

Nee jissie, don't go there Captain. Die bike se voorwiel was damn naby aan die muur toe ek die eerste keer die starter druk. Kan jy imagine ek ry die KLR deur die muur?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 28, 2008, 09:51:54 pm
:laughing4:
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 28, 2008, 10:00:50 pm
Seems like my KLR eats brake pads for breakfast front ones almost gone after 12000km 
Title: Re: KLR650 Restoration....Please help......
Post by: Lootch67 on January 29, 2008, 01:39:34 am
I get less than that - probably about 8k from the last set. I do a lot of town riding though.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 29, 2008, 12:39:01 pm
Seems like my left front shock is bent and the handle bars are bent too..... restoring the KLR never stops...

Anybody got a shock for me???
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on January 29, 2008, 03:02:41 pm
Fork (Inner tube): Disassemble and get it straightened. Works as long as there's no kink in the tube. Get someone who knows what he's doing.
Handlebars: Throw away, buy new.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 29, 2008, 03:42:14 pm
Fork (Inner tube): Disassemble and get it straightened. Works as long as there's no kink in the tube. Get someone who knows what he's doing.
Handlebars: Throw away, buy new.

Jip the inner tube. I don't think there is any kinks in the tube.

There is a company in PE that manufactures hydraulic cylinders to custom sizes, i wonder if they can straighten tubes? ::)

Yah i want pro tapers anyway :D
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on January 29, 2008, 04:27:39 pm
Seems like my left front shock is bent and the handle bars are bent too..... restoring the KLR never stops...

Anybody got a shock for me???
Ahem... how did that happen? :-)
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on January 29, 2008, 05:08:23 pm
Fork (Inner tube): Disassemble and get it straightened. Works as long as there's no kink in the tube. Get someone who knows what he's doing.
Handlebars: Throw away, buy new.

Jip the inner tube. I don't think there is any kinks in the tube.

There is a company in PE that manufactures hydraulic cylinders to custom sizes, i wonder if they can straighten tubes? ::)

Yah i want pro tapers anyway :D

They can be straightened, and the Japanese stuff is "easier" than some of the European stuff which uses CrMo tubes etc.

Any engineering shop with some Vee Blocks and an Hydraulic press can do it.

Welsh
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 29, 2008, 08:03:19 pm
Common out with it Cappy. You were working on that part of the bike only a few weeks ago, now it's bent? What's going on here?
 >:D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 29, 2008, 09:08:00 pm
Don't know... only noticed the shock were bent when i had it stripped on the table.... must have been the previous owner.... i'll never buy a second hand bike again without knowing the previous owner.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on January 29, 2008, 09:15:12 pm
No man wait until you yourself put a descent dent in your machine, that's when you really start loving it!
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 29, 2008, 09:19:39 pm
Fork (Inner tube): Disassemble and get it straightened. Works as long as there's no kink in the tube. Get someone who knows what he's doing.
Handlebars: Throw away, buy new.

Jip the inner tube. I don't think there is any kinks in the tube.

There is a company in PE that manufactures hydraulic cylinders to custom sizes, i wonder if they can straighten tubes? ::)

Yah i want pro tapers anyway :D

They can be straightened, and the Japanese stuff is "easier" than some of the European stuff which uses CrMo tubes etc.

Any engineering shop with some Vee Blocks and an Hydraulic press can do it.

Welsh

Went to our engineering shop at work and the guys said no problem we have the V blocks and press and they said they straighten hydraulic cylinders all the time. ;D

I feel another job coming up. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on January 29, 2008, 09:21:49 pm
No man wait until you yourself put a descent dent in your machine, that's when you really start loving it!

Jaja ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on January 30, 2008, 05:52:02 am
Fork (Inner tube): Disassemble and get it straightened. Works as long as there's no kink in the tube. Get someone who knows what he's doing.
Handlebars: Throw away, buy new.

Jip the inner tube. I don't think there is any kinks in the tube.

There is a company in PE that manufactures hydraulic cylinders to custom sizes, i wonder if they can straighten tubes? ::)

Yah i want pro tapers anyway :D

They can be straightened, and the Japanese stuff is "easier" than some of the European stuff which uses CrMo tubes etc.

Any engineering shop with some Vee Blocks and an Hydraulic press can do it.

Welsh

Went to our engineering shop at work and the guys said no problem we have the V blocks and press and they said they straighten hydraulic cylinders all the time. ;D

I feel another job coming up. ;D

I have got a whole series of "T" shirts, been there done that.

Welsh  8)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 06, 2008, 08:02:32 pm
Received my bolt upgrade kit from Le Cap today. Yippee can wait to put it together. ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 16, 2008, 01:33:13 pm
Did some work on the KLR today....  :D

Stage one weight reduction mod  :D  Getting rid of the side stand switch.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 16, 2008, 01:35:14 pm
Added some nice new stainless steel bolts that i got from Le Cap. ;D

Clutch lever clamp.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 16, 2008, 01:38:54 pm
Added some new stickers too..  ;D

I put the little KTM sticker on which i got from Paulsky because my KLR feels like an armgat KTM.... :laughing4:

Spot the nice new shiny bolts that hold the side covers.
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on February 16, 2008, 05:52:28 pm
(Shakes head sadly and walks away with hunched shoulders, thinking about the poor state of affairs if KLR owners starts putting KTM stickers on their bikes.

It's like the okes around GP that have got little horsey Ferrari stickers on the back of their klapped out fordjies. Ai Ai Ai.

 :'(

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 16, 2008, 10:27:58 pm
Haha dit is so Uncle ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 19, 2008, 07:20:47 pm
Tonight i just feel like getting rid of the KLR and buying another bike.

I'm a bit of a perfectionist and the front wheel of the bike always aims left. So i took the shocks out and checked them on some v-blocks and a dial gauge. The were found to be straight. Then i refitted the shocks, i loosened the bottom fork clamps and loosened the steering nut. I bend the wheel as straight as it can be. Tightened all the nuts and slowly the wheel creeped back to aim a little left.

I then rode to the nearest petrol station to fill the tank. Back home the F$%king thing is back in the same position it was when i started stripping.....

Seems like i'll never have straight wheels  :'(
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on February 19, 2008, 07:41:40 pm
Captain, it sounds like something else might be out of wack, but I find it strange that the wheel seems to take a little while to creep to the left. Sounds like something is working itself loose.

Have you had the bike checked out by a pro yet? I know this sounds like a cop - out, but sometimes people who've worked with bikes all their lives can tell you the answer quickly and save you the pain.

Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 19, 2008, 08:02:27 pm
True Uncle i'm just feeling really negative tonight.... the bike seems like an endless money pit.... i don't know why i didn't buy a new one. :(
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 19, 2008, 08:05:04 pm
I think the clamps are skew...
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on February 19, 2008, 08:09:48 pm
I think the clamps are skew...

????? starting point?

Hey Captain and deprive the Forum of this 34 page epic  ;D ;D
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on February 19, 2008, 08:13:21 pm
True Uncle i'm just feeling really negative tonight.... the bike seems like an endless money pit.... i don't know why i didn't buy a new one. :(

Don't know about checking out the clamps, as I said, perhaps get some pro advice. As for the money pit thing, everytime I start feeling like that I look at the total amount I've blown on the bike and then subtract the amount spent just on nice things, not essentials. I also take off stuff like service costs and stuff I'd have to have done in any case. The amount I'm left with is actually very little.

Cheer up CS, have a cold one and phone a girlfriend. Now THAT'S a pit of money  >:D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 19, 2008, 08:22:59 pm
True Uncle i'm just feeling really negative tonight.... the bike seems like an endless money pit.... i don't know why i didn't buy a new one. :(

Don't know about checking out the clamps, as I said, perhaps get some pro advice. As for the money pit thing, everytime I start feeling like that I look at the total amount I've blown on the bike and then subtract the amount spent just on nice things, not essentials. I also take off stuff like service costs and stuff I'd have to have done in any case. The amount I'm left with is actually very little.

Cheer up CS, have a cold one and phone a girlfriend. Now THAT'S a pit of money  >:D


Thanks Uncle i will ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 19, 2008, 08:25:06 pm
I think the clamps are skew...

????? starting point?

Hey Captain and deprive the Forum of this 34 page epic  ;D ;D

What do you mean by "Starting point"?

Had lots of fun with this bike so far.... i've taken it apart so many times my neighbours think i'm crazy ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on February 19, 2008, 08:30:15 pm
I think the clamps are skew...

????? starting point?

Hey Captain and deprive the Forum of this 34 page epic  ;D ;D

What do you mean by "Starting point"?

Had lots of fun with this bike so far.... i've taken it apart so many times my neighbours think i'm crazy ;D

OK you are crazy and I look forward to discussing insanity, Druids, KLR,s and beer in the future.

Loosening all bolts and pumping the suspension is a starting point to aligning the forks, of course not too much  loosening or it will sit a ittle lower.

Welsh 
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 19, 2008, 08:45:19 pm
I think the clamps are skew...

????? starting point?

Hey Captain and deprive the Forum of this 34 page epic  ;D ;D

What do you mean by "Starting point"?

Had lots of fun with this bike so far.... i've taken it apart so many times my neighbours think i'm crazy ;D

OK you are crazy and I look forward to discussing insanity, Druids, KLR,s and beer in the future.

Loosening all bolts and pumping the suspension is a starting point to aligning the forks, of course not too much  loosening or it will sit a ittle lower.

Welsh 

Okay me now understand ;D

I did exactly that tonight. Loosened all the bolts. Aligned the wheel perfectly. Got on the bike. Rode around the block and the wheel was skew again.... :(
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on February 19, 2008, 08:52:34 pm
I think the clamps are skew...

????? starting point?

Hey Captain and deprive the Forum of this 34 page epic  ;D ;D

What do you mean by "Starting point"?

Had lots of fun with this bike so far.... i've taken it apart so many times my neighbours think i'm crazy ;D

OK you are crazy and I look forward to discussing insanity, Druids, KLR,s and beer in the future.

Loosening all bolts and pumping the suspension is a starting point to aligning the forks, of course not too much  loosening or it will sit a ittle lower.

Welsh 

Okay me now understand ;D

I did exactly that tonight. Loosened all the bolts. Aligned the wheel perfectly. Got on the bike. Rode around the block and the wheel was skew again.... :(

Captain, please tell me you tightened those bolts again before riding around the block?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 19, 2008, 09:00:01 pm
I think the clamps are skew...

????? starting point?

Hey Captain and deprive the Forum of this 34 page epic  ;D ;D

What do you mean by "Starting point"?

Had lots of fun with this bike so far.... i've taken it apart so many times my neighbours think i'm crazy ;D

OK you are crazy and I look forward to discussing insanity, Druids, KLR,s and beer in the future.

Loosening all bolts and pumping the suspension is a starting point to aligning the forks, of course not too much  loosening or it will sit a ittle lower.

Welsh 

Okay me now understand ;D

I did exactly that tonight. Loosened all the bolts. Aligned the wheel perfectly. Got on the bike. Rode around the block and the wheel was skew again.... :(

Captain, please tell me you tightened those bolts again before riding around the block?

:laughing4: sharp Uncle ;)

Yes i did ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 09:19:10 am
Picture for those who are interested.  :-\
Title: Re: KLR650 Restoration....Please help......
Post by: bobnob on February 20, 2008, 09:28:33 am
maybe its torque steer   >:D >:D >:D
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on February 20, 2008, 09:47:41 am
Just loosen the bolts holding the fender and twist it till it aligns with the skew wheel. Nobody will know better.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 09:55:11 am
Just loosen the bolts holding the fender and twist it till it aligns with the skew wheel. Nobody will know better.

Ja but Groenie the handle bars line up with the fender.... so da wheel must be skew.
Title: Re: KLR650 Restoration....Please help......
Post by: Pom on February 20, 2008, 10:03:23 am
I don't kmow much about this thread at all, and I do't have time to read it all, but I have seen this before.
On a old bike I had the same thing kept happening, it turned out to be one of the front shocks.

The seals had been replaced and the guy who did the job had one spring and a spacer upside down, this makes
the travel on the fork different and misaligns the front wheel.

My 2c worth, maybe check it out if you haven't already
Title: Re: KLR650 Restoration....Please help......
Post by: Biesie on February 20, 2008, 10:04:07 am
Just loosen the bolts holding the fender and twist it till it aligns with the skew wheel. Nobody will know better.

Ja but Groenie the handle bars line up with the fender.... so da wheel must be skew.

Djy wassi dalk gasuip nie  ??? ;D ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 10:06:16 am
I don't kmow much about this thread at all, and I do't have time to read it all, but I have seen this before.
On a old bike I had the same thing kept happening, it turned out to be one of the front shocks.

The seals had been replaced and the guy who did the job had one spring and a spacer upside down, this makes
the travel on the fork different and misaligns the front wheel.

My 2c worth, maybe check it out if you haven't already

Haven't checked it but the wheel is skew even if it is hanging in the air in other words with the shocks fully extended.
Title: Re: KLR650 Restoration....Please help......
Post by: Pom on February 20, 2008, 10:06:47 am
Also measure the sag on the fork springs to check if they are not worn out and outside
their tolerance limits. Do you have the correct weight oil in the forks plus the
correct volume?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 10:07:04 am
Just loosen the bolts holding the fender and twist it till it aligns with the skew wheel. Nobody will know better.

Ja but Groenie the handle bars line up with the fender.... so da wheel must be skew.

Djy wassi dalk gasuip nie  ??? ;D ;D

Nee maar ek wens ek was ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Pom on February 20, 2008, 10:07:57 am
I don't kmow much about this thread at all, and I do't have time to read it all, but I have seen this before.
On a old bike I had the same thing kept happening, it turned out to be one of the front shocks.

The seals had been replaced and the guy who did the job had one spring and a spacer upside down, this makes
the travel on the fork different and misaligns the front wheel.

My 2c worth, maybe check it out if you haven't already

Haven't checked it but the wheel is skew even if it is hanging in the air in other words with the shocks fully extended.

It would be if the spacers are incorrect, even at the bottom of the travel with no weight on it
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 10:08:22 am
Also measure the sag on the fork springs to check if they are not worn out and outside
their tolerance limits. Do you have the correct weight oil in the forks plus the
correct volume?

Jip all correct. Did the shocks and seals a while ago.... it was skew before and after the oil change.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 10:09:38 am
I don't kmow much about this thread at all, and I do't have time to read it all, but I have seen this before.
On a old bike I had the same thing kept happening, it turned out to be one of the front shocks.

The seals had been replaced and the guy who did the job had one spring and a spacer upside down, this makes
the travel on the fork different and misaligns the front wheel.

My 2c worth, maybe check it out if you haven't already

Haven't checked it but the wheel is skew even if it is hanging in the air in other words with the shocks fully extended.

It would be if the spacers are incorrect, even at the bottom of the travel with no weight on it

I think i should take it to a Pro.... ek is gatvol :(
Title: Re: KLR650 Restoration....Please help......
Post by: Pom on February 20, 2008, 10:11:33 am
I know that feeling all too well >:(
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 07:33:00 pm
Just as reference....

The thread on KLR650.net on my skew front wheel...  ;)

http://www.klr650.net/forums/showthread.php?t=38646
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on February 20, 2008, 07:35:56 pm
I don't kmow much about this thread at all, and I do't have time to read it all, but I have seen this before.
On a old bike I had the same thing kept happening, it turned out to be one of the front shocks.

The seals had been replaced and the guy who did the job had one spring and a spacer upside down, this makes
the travel on the fork different and misaligns the front wheel.

My 2c worth, maybe check it out if you haven't already

Haven't checked it but the wheel is skew even if it is hanging in the air in other words with the shocks fully extended.

Trust me, POM is talkin the business, check it.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 20, 2008, 07:38:26 pm
I don't kmow much about this thread at all, and I do't have time to read it all, but I have seen this before.
On a old bike I had the same thing kept happening, it turned out to be one of the front shocks.

The seals had been replaced and the guy who did the job had one spring and a spacer upside down, this makes
the travel on the fork different and misaligns the front wheel.

My 2c worth, maybe check it out if you haven't already

Haven't checked it but the wheel is skew even if it is hanging in the air in other words with the shocks fully extended.

Trust me, POM is talkin the business, check it.

It actually makes sense....

If the travel is different and my weight is pushing down on the bike it will make the forks go skew.... ;D
Title: Re: KLR650 Restoration....Please help......
Post by: edgy on February 21, 2008, 07:31:19 am
Captain,off you go back to Chris Shinn ;D
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on February 21, 2008, 08:05:08 am
Cappie, I was thinking about this on my way home last night. You bent your handlebar when you tried to drown your bike in that river.......No?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 21, 2008, 08:05:46 am
Captain,off you go back to Chris Shinn ;D

Ja seems like it ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 21, 2008, 08:14:39 am
Cappie, I was thinking about this on my way home last night. You bent your handlebar when you tried to drown your bike in that river.......No?

Ja die f*kken ding is ook gebuig ;D

I'm lining up the front wheel with the handle bar brackets not the actual handle bars, cause i know they are bent.. i wanna sort out the front wheel before i get my Pro-tapers ;)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 21, 2008, 08:19:27 am
Al wat straight is op my bike is ek..... bhahaha :D
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on February 21, 2008, 10:59:39 am
Check in this order:

Remove non OEM fork stabiliser if any.

Fork tubes: Clamp lower end in vice (soft clamps please!) and turn inner tube by hand with dial feeler pointed onto the end. Runout should be (near) zero. Try to turn carefully and continuously to avoid bending the tube towards or away from the dial.

If OK: Take front axle and roll over glass plate or granite counter top to see if it's bent.

If OK: Push fork gaitors down as far as possible to expose some length of both fork tubes. Ideally remove gaitors. Look at fork innertubes at level from some distance from the side. The tubes must be clamped and torqued in the triple clamps. If they are not parallel your triple clamps are skew. If you have something with your eyes get a piece of floatglass (some 15x30cm) and put it flat onto the inner tubes. If it niggles your triple clamps are skew.

If OK throw non OEM fork stabiliser away.

Is your front fairing assembly straight? (Rare on a KLR that has been dropped a few times) A skew nose often gives the optical impression of a skew fork.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 21, 2008, 12:24:23 pm
Thanks for the advice Le Cap.... i'll try again at a later stage to fix this problem.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 23, 2008, 02:44:52 pm
Installed the high strength subframe and footpeg bolts today.
Title: Re: KLR650 Restoration....Please help......
Post by: Welsh on February 23, 2008, 03:28:22 pm
Installed the high strength subframe and footpeg bolts today.

Ja better than a diet  ;D ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 23, 2008, 03:36:30 pm
Installed the high strength subframe and footpeg bolts today.

Ja better than a diet  ;D ;D

I am on a diet. Lost 3kg in just over 3 weeks ;).... aiming for 20kg ;)
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on February 23, 2008, 04:32:47 pm
Wow Cappy, then you're going to be only 15 Kilos heavier than me and ALL MY LUGGAGE PUT TOGETHER! >:D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 23, 2008, 05:04:59 pm
I'm 118kg at the moment. Hopefully i can go to 100kg.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on February 29, 2008, 01:29:10 pm
Installed new brake pads on the front today. Fitted EBC.

Had SBS on. They lasted 13000km.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 02, 2008, 03:55:53 pm
It was about time ;D

(http://i198.photobucket.com/albums/aa313/heinb7/Grahamstown%20010308/Pic22.jpg)
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on March 02, 2008, 07:43:58 pm
Bwahahaha!

Ag lekker lag ek nou. But at least it gives you something to mod on the bike, hey? Captain, design yourself a lekker pooratech holder that will never break, it will keep you busy for a day or two! Actually, I thought this was one of the first mods you'd have done.



Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 02, 2008, 07:49:37 pm
Uncle i really thought it would clear the wheel. The previous owner did move the plate and in all the rough riding i did it never came off.

I want to make a smaller plate and mount it like Groenie but i'm scared of the kk.
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on March 02, 2008, 08:46:02 pm
Uncle i really thought it would clear the wheel. The previous owner did move the plate and in all the rough riding i did it never came off.

I want to make a smaller plate and mount it like Groenie but i'm scared of the kk.
KLR's rarely exceed the speed limit and are thus invisible to the KK but I agree, rather stay legal and not attract their attention. :-(
Title: Re: KLR650 Restoration....Please help......
Post by: dustsucker on March 04, 2008, 10:16:42 am
Uncle i really thought it would clear the wheel. The previous owner did move the plate and in all the rough riding i did it never came off.

I want to make a smaller plate and mount it like Groenie but i'm scared of the kk.

Captain..have to ask, what does 'kk' stand for?
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on March 04, 2008, 10:30:26 am
Aag nee, julle Derbi ryers darem.......KK = Koelte K0nt
Title: Re: KLR650 Restoration....Please help......
Post by: dustsucker on March 04, 2008, 11:22:57 am
Faanx Groenie. :laughing4:
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 04, 2008, 11:32:12 am
Aag nee, julle Derbi ryers darem.......KK = Koelte K0nt


Hulle sit in die koelte langs die pad en wag vir my om verby te ry. ;)
Title: Re: KLR650 Restoration....Please help......
Post by: dustsucker on March 04, 2008, 12:52:32 pm
kry eergister `n fine van ons "around sa trip".  300 bokke buite Kuruman, glo 86km/h in `n 60 zone.....regte ou flou dorp nog daarby.  Wil nog die ou bel en vra of hy van sy hol af is, waar kan `n KLR so vinnig ry?
Title: Re: KLR650 Restoration....Please help......
Post by: lecap on March 05, 2008, 10:11:02 am
Aag nee, julle Derbi ryers darem.......KK = Koelte K0nt


And in English?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2008, 10:32:35 am
Aag nee, julle Derbi ryers darem.......KK = Koelte K0nt


And in English?

Haha Le Cap   

I'm not writing it here.... it seems so much worse in English :D
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on March 05, 2008, 03:25:47 pm
Aag nee, julle Derbi ryers darem.......KK = Koelte K0nt


And in English?

Haha Le Cap   

I'm not writing it here.... it seems so much worse in English :D
Mmmmm now what to call them in English? The SS = Shade S**ts :-)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2008, 03:29:11 pm
Aag nee, julle Derbi ryers darem.......KK = Koelte K0nt


And in English?

Haha Le Cap   

I'm not writing it here.... it seems so much worse in English :D
Mmmmm now what to call them in English? The SS = Shade S**ts :-)

;D
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on March 05, 2008, 03:41:02 pm
It was about time ;D
Ek sien nou eers daai axle nut is links in plaas van regs soos my KLR? What side should it be on?
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 05, 2008, 03:49:25 pm
It was about time ;D
Ek sien nou eers daai axle nut is links in plaas van regs soos my KLR? What side should it be on?

No clue
Title: Re: KLR650 Restoration....Please help......
Post by: Groenie on March 06, 2008, 07:48:33 am
It was about time ;D
Ek sien nou eers daai axle nut is links in plaas van regs soos my KLR? What side should it be on?

Do you care? I find it easier to insert the axle from the right hand side, the caliper bracket helps to keep the axle in place while you get wheel aligned.
Title: Re: KLR650 Restoration....Please help......
Post by: Kampies on March 06, 2008, 08:43:49 am
Nee man cappie.

Just ride without a plate! The KK's isint so strict in P.E. Just leave the broken plate in you top box, for the one day that they do pull over. Im sure you will be able to tune the oke that it happened just now when you bonny hopped over a sidewalk... ;D ;D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2008, 09:14:36 am
Nee man cappie.

Just ride without a plate! The KK's isint so strict in P.E. Just leave the broken plate in you top box, for the one day that they do pull over. Im sure you will be able to tune the oke that it happened just now when you bonny hopped over a sidewalk... ;D ;D

Ek is badluck man
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on March 06, 2008, 11:19:59 am
It was about time ;D
Ek sien nou eers daai axle nut is links in plaas van regs soos my KLR? What side should it be on?

Do you care? I find it easier to insert the axle from the right hand side, the caliper bracket helps to keep the axle in place while you get wheel aligned.
You have been working on em longer than me so I trust your judgement Groenie! :-)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2008, 11:49:10 am
It was about time ;D
Ek sien nou eers daai axle nut is links in plaas van regs soos my KLR? What side should it be on?

Do you care? I find it easier to insert the axle from the right hand side, the caliper bracket helps to keep the axle in place while you get wheel aligned.
You have been working on em longer than me so I trust your judgement Groenie! :-)

Ooooeeee brave move :D
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 06, 2008, 11:51:07 am
Got my new nuberplate will fit it after i've done the KLR stage 2 weight reduction mod.... :D

Getting rid of all the useless cr*p that holds the standard plate.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 08, 2008, 02:51:10 pm
New number plate and relocated  :)
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 08, 2008, 02:53:04 pm
GPS mounted but i'm going to build another mount. This one is only temporary. :)
Title: Re: KLR650 Restoration....Please help......
Post by: LeonDude on March 08, 2008, 04:08:42 pm
Captain, I checked a couple of GPS mounts out today, fitted on other okes bikes. They've got plenty of rubber between the GPS and whatever piece of the handle or bike it's fitted to, to stop vibrations.

Just a thought.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 08, 2008, 07:20:34 pm
Thanks Uncle i'm working on it.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 09, 2008, 09:04:34 pm
When should i replace my chain and sprockets? It looks buggered...

I'm estimating the set i'm currently running has done more than 20 000km...
Title: Re: KLR650 Restoration....Please help......
Post by: RobC on March 09, 2008, 11:07:14 pm
When should i replace my chain and sprockets? It looks buggered...

I'm estimating the set i'm currently running has done more than 20 000km...
Play on the rear sprocket, you should not be able to lift the links off the teeth and the teeth of the sprockets should not look like claws. Check the manual for exact specs.
Title: Re: KLR650 Restoration....Please help......
Post by: El Zeffo on March 10, 2008, 07:06:18 am
I think my sprockets are close to replacement.....
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 15, 2008, 04:44:00 pm
Built a pooratech GPS bracket this week and it works lekker.

Used a piece of offcut aluminum and two pipe shackles, some velcro and some glue :D

Also bought a little power plug on the web and fitted it.

I glued the velcro to the GPS with contact adhesive which can be easily removed with some acetone or alcohol. ;)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 15, 2008, 04:45:42 pm
Looks like my battery is one its way out :(

Looks at the voltage in the above picture.
Title: Re: KLR650 Restoration....Please help......
Post by: GreenMachine on March 15, 2008, 08:03:33 pm
GPS mounted but i'm going to build another mount. This one is only temporary. :)

Captain, what is that thing one the cross-bar ?
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 15, 2008, 08:16:20 pm
GPS mounted but i'm going to build another mount. This one is only temporary. :)

Captain, what is that thing one the cross-bar ?

It is a pump ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Carnivore on March 15, 2008, 08:22:07 pm
Cappie, here is a GPS track-set for you.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on March 15, 2008, 08:24:42 pm
GPS mounted but i'm going to build another mount. This one is only temporary. :)

Captain, what is that thing one the cross-bar ?

It is a pump ;D

Funny that. The first time someone posted a pic of a bicycle pump on a motorbike a few months back I thought it was hilarious, I even remember joking he must please post the video of how he tests the pump. I think it might have been on the pooratech thread. Now guess who's got a pump in his toolkit?

Ha ha, jokes on me!
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 15, 2008, 08:27:11 pm
Thanks ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 15, 2008, 08:36:18 pm
Uncle pumping a bike wheel with a bicycle pump is not that bad.... try blowing it up with your lungs when you don't have a pump.... now thats what i call funny :D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 01:21:26 pm
I think the Restorartion is now finished only boring maintenance remain....

This KLR is now for sale.

R25k neg with all the goodies.....

2005 Model

Pannier bags
Top box
GPS and all the brackets, power connections, software
Stainless footpegs
Upgraded gearlever
Upgraded hand guards
Doo hickey done
Lugguage plate
New chains and sprockets
Anakees still good
Penta Exhaust
T-mod done
Airbox mod done
New clutch cable
Spare sealed wheel bearings

Bla bla bla many more....

Spent about R12k on the bike

Bargain at R25k ;)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: edgy on March 26, 2008, 01:26:11 pm
CS are you now going to start a KTM restoration thread? ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: bobnob on March 26, 2008, 01:26:39 pm
I think the Restorartion is now finished only boring maintenance remain....

This KLR is now for sale.

R25k neg with all the goodies.....

Pannier bags
Top box
GPS and all the brackets, power connections, software
Stainless footpegs
Upgraded gearlever
Upgraded hand guards
Doo hickey done
Lugguage plate
New chains and sprockets
Anakees still good
Penta Exhaust
T-mod done
Airbox mod done
New clutch cable
Spare sealed wheel bearings

Bla bla bla many more....

Spent about R12k on the bike

Bargain at R25k ;)

does that mean this thread will come to an end  :o

 ;D ;D ;D

please buy a new v-strom - i dont know if i will survive a

V-STROM Restoration...Please help... thread  >:D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 01:27:37 pm
CS are you now going to start a KTM restoration thread? ;D

Nope.... the KTM will make me bankrupt
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: edgy on March 26, 2008, 01:28:52 pm
What then?......not the strom!
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 01:29:40 pm
I think the Restorartion is now finished only boring maintenance remain....

This KLR is now for sale.

R25k neg with all the goodies.....

Pannier bags
Top box
GPS and all the brackets, power connections, software
Stainless footpegs
Upgraded gearlever
Upgraded hand guards
Doo hickey done
Lugguage plate
New chains and sprockets
Anakees still good
Penta Exhaust
T-mod done
Airbox mod done
New clutch cable
Spare sealed wheel bearings

Bla bla bla many more....

Spent about R12k on the bike

Bargain at R25k ;)

does that mean this thread will come to an end  :o

 ;D ;D ;D

please buy a new v-strom - i dont know if i will survive a

V-STROM Restoration...Please help... thread  >:D

Thinking of getting a second hand slightly used 650 Vstrom then add lotsa goodies.... crash bars, bashplate, luggage and new GPS ;)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 01:30:26 pm
What then?......not the strom!

I think the 650 strom suits my riding style well ;)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 01:30:57 pm
So who's going to buy it? ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 01:31:22 pm
For my forum buddies it is R24k ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: bobnob on March 26, 2008, 01:36:40 pm
For my forum buddies it is R24k ;D

if you sell it to a forum member then this thread will never end  ::)

we might have to set the bike on fire at the next bash to get rid of this thread  >:D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 01:38:45 pm
For my forum buddies it is R24k ;D

if you sell it to a forum member then this thread will never end  ::)

we might have to set the bike on fire at the next bash to get rid of this thread  >:D

I know you love it ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 03:57:59 pm
For sale

http://www.wilddog.za.net/forum/index.php?topic=16235.msg253082#msg253082
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Groenie on March 26, 2008, 08:55:51 pm
Ai ai ai. Aag nee man, ek dog jy het hom nou net mooi uit gesort.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 26, 2008, 09:01:59 pm
Ons sal maar sien. Dalk hou ek hom. Die reserwe bank en Trevor manual maak my bang.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: RobC on March 27, 2008, 09:30:13 pm
What a shame... I learn't a lot on this thread...
Maar as mens eers op 'n ander bike verlief geraak het dan is daar nie keer nie.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 27, 2008, 10:28:43 pm
Ag nee ek is nog lief vi my KLR, wens ek kan altwee hou maar dan moet my kar gaan.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Groenie on March 28, 2008, 08:30:32 am
Verkoop die kar. Jy gaan die KLR mis as jy hom verkoop.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 28, 2008, 10:01:24 am
Verkoop die kar. Jy gaan die KLR mis as jy hom verkoop.

Ek dink ek moet die kar swaai :D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on March 29, 2008, 05:14:57 am
I know how this kind of message makes your KLR react. Be careful how far you ride this weekend, something is going to go. Please remember to take pics.
 ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 29, 2008, 09:16:39 am
Dit reen in PE :(
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: RobC on March 29, 2008, 09:29:50 am
Dit reen in PE :(
See... KLR's can change the weather when upset.  ::)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Carnivore on March 29, 2008, 09:56:01 pm
The other day, the Captain came to visit. (he said it was to do with the GPS mount, but I really think he wanted to eyeball a young lady..)
Anyway, when the KLR saw the very worn T63 on the back of my F650 in the depths of the garage, it refused to go any further - just sat there and sulked. Only when Cap was ready to go, did the KLR condescend to start and get the heck out of there.

I had to speak nicely to my bike - it was very hurt that the KLR was so iffy.

Really...
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 29, 2008, 11:01:39 pm
;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on March 30, 2008, 07:43:39 am
I knew it!
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 30, 2008, 09:42:24 am
BMWs are known to be to sensitive ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Iron Shark on March 30, 2008, 10:23:59 am
So CS have you taken a 650 vstrom for a spin yet? I'm sure you'll fall in love with it for sure... "monkey" has just bought himself one and is loving it!!!  :) See if you can get one for a demo ride then make your decision... after the ride there will be no stopping you and the poor old KLR sal maar die pad moet vat...  :(
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 30, 2008, 12:40:55 pm
So CS have you taken a 650 vstrom for a spin yet? I'm sure you'll fall in love with it for sure... "monkey" has just bought himself one and is loving it!!!  :) See if you can get one for a demo ride then make your decision... after the ride there will be no stopping you and the poor old KLR sal maar die pad moet vat...  :(

Yes i have taken one for a ride. It rides excellent.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on March 30, 2008, 03:37:52 pm
Captain what mod are you going to do next on your KLR?
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on March 30, 2008, 03:39:42 pm
Captain what mod are you going to do next on your KLR?

No mods.... only need to fit the sprockets and chain soon.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on April 02, 2008, 05:06:53 pm
The KLR got new chain and sprockets today... looks really purty ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: RobC on April 03, 2008, 12:13:50 am
Mine came back from it's 12000k service... feels smoother as all the chains and stuff are adjusted... no need for shims as the valve clearance was still in spec. Thanks Johan.
Maar die volgende keer doen ek alles self... warranty expires in June.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on April 05, 2008, 04:41:28 pm
Used some clean green to clean the bike.

First time i ever user clean green...... the stuff is absolutely great..... I'll buy it in big bottles from now on.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Iron Shark on April 05, 2008, 04:46:41 pm
Come on CS, take a ride out to the "Adult Rally" Maitlands 4x4 area and dirty that KLR again!! You know you want to, be a devil...   ;)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on April 05, 2008, 04:54:28 pm
Come on CS, take a ride out to the "Adult Rally" Maitlands 4x4 area and dirty that KLR again!! You know you want to, be a devil...   ;)

Nah ek is 'n soet seuntjie
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on April 26, 2008, 06:00:08 pm
The End :)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on April 26, 2008, 06:07:16 pm
 :angel12:
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Groenie on April 26, 2008, 10:38:42 pm
Thanx for a lekker thread, Cappie. All KLR riders learnt something from it.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Welsh on April 27, 2008, 07:44:22 am
A classic thread, are the mods gonna lock and leave it or what?
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on April 27, 2008, 09:48:07 am
Don't think there is a reason to lock it... maybe someone wanna continue
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on June 26, 2008, 03:07:12 pm
Bump

Just reading through this thread.... was an absolute jol to do it.....

Valuable info for all KLR owners....

Proudly South African :D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: bobnob on June 26, 2008, 03:10:07 pm
please mods lock this thread  ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: RobC on June 27, 2008, 08:22:42 am
please mods lock this thread  ;D
Hey... los ons KLR ryers se goeters uit! >:D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on July 24, 2008, 12:36:50 pm
Anyone recognize this bike  ::)

Matt the American is currently in Namibia...

Pics also taken in Namibia

(http://farm4.static.flickr.com/3133/2671385404_196ec8964b.jpg?v=0)

(http://farm4.static.flickr.com/3246/2670539589_a20a1d325c.jpg?v=0)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Watty on July 24, 2008, 02:36:47 pm
Ha, now we know why there is a shortage of D/S tyres at the moment  >:D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: RobC on July 24, 2008, 11:20:14 pm
That KLR looks like it is loaded like a Transkei taxi! :laughing4:
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on July 25, 2008, 07:06:53 am
I posted the pics so everybody will know why the frame snapped if it does.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Iron Shark on July 27, 2008, 09:04:44 am
I posted the pics so everybody will know why the frame snapped if it does.

Shame CS don't wish the man such bad luck....  ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on July 27, 2008, 10:15:33 am
I posted the pics so everybody will know why the frame snapped if it does.

Shame CS don't wish the man such bad luck....  ;D

I'm not wishing him bad luck i am being realistic.... :)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Iron Shark on July 27, 2008, 01:40:59 pm
I posted the pics so everybody will know why the frame snapped if it does.

Shame CS don't wish the man such bad luck....  ;D

I'm not wishing him bad luck i am being realistic.... :)

Ag ja man ek verstaan, I remember about his wobble type beginnings at your spot when he left...   :imaposer: :imaposer:
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on July 27, 2008, 02:03:24 pm
For the interested parties :)

http://www.africandownshift.com/
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on November 08, 2008, 10:14:16 pm
Update  ;D

Namibia

(http://farm4.static.flickr.com/3148/2714579264_9ed5e88c59.jpg?v=0)

Gabon

(http://farm4.static.flickr.com/3207/2983676907_b5a4f8d991.jpg?v=0)

Gabon.... don't know where the headlight is...  :o

(http://farm4.static.flickr.com/3285/2983672959_9410b2030e.jpg?v=0)

(http://farm4.static.flickr.com/3187/2983651861_dcb0cea5ea.jpg?v=0)

(http://farm4.static.flickr.com/3001/2984503510_b933134530.jpg?v=0)

(http://farm4.static.flickr.com/3238/2983644833_48d724a315.jpg?v=0)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Red Adventure on November 08, 2008, 10:59:06 pm
You've got to get this bike back when he's done and then start this thread all over again!!! might just get you to the 20k post mark :imaposer:
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on November 08, 2008, 11:01:59 pm
You've got to get this bike back when he's done and then start this thread all over again!!! might just get you to the 20k post mark :imaposer:

I miss the bike.... i'm guessing its done about 75 000 km by now.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: >>Thump░C on December 10, 2009, 11:53:57 pm
Cappie, When you getting this bike back?
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on December 11, 2009, 06:01:33 am
Nah i think i'm going for the DR650....

But if someone can recover this one somewhere in Northern Africa it would be great. ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Ganjora on December 11, 2009, 06:08:28 am
Nah i think i'm going for the DR650..... ;D

do it
join the SSS
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on December 11, 2009, 06:17:50 am
Nah i think i'm going for the DR650..... ;D

do it
join the SSS

How much are they new?
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Ganjora on December 11, 2009, 06:20:47 am
I seem to recall kykdaar saying they'd come down from the 67 I paid to only 62 gorillas
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on December 11, 2009, 06:22:35 am
I seem to recall kykdaar saying they'd come down from the 67 I paid to only 62 gorillas

Dit is ook maar fokken baie...
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on December 11, 2009, 06:32:40 am
I will wait for Kykdaar to sell his >:D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on December 11, 2009, 07:39:02 am
I don't think you're going to part him with his bike soon!  :biggrin:

Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on December 11, 2009, 07:53:41 am
I don't think you're going to part him with his bike soon!  :biggrin:



Can we not start a lewensgevaarlik rumor ::)
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on December 11, 2009, 08:01:49 am
Maybe start telling how good he will look on a 1200GS?

BTW, just don't think I can get that 10W oil around here, not even the bike service shop could sell me some. How much of the stuff do I need?

Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on December 11, 2009, 09:34:42 am
Maybe start telling how good he will look on a 1200GS?

BTW, just don't think I can get that 10W oil around here
, not even the bike service shop could sell me some. How much of the stuff do I need?



But how is that possible?  ???

Did you try bike shops?  :biggrin:
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: LeonDude on December 11, 2009, 12:11:13 pm
Found some, R190 for a liter, damn  :P
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on December 11, 2009, 01:02:07 pm
Found some, R190 for a liter, damn  :P

Dis die prys ja.
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: zetman on January 27, 2012, 11:16:51 pm
moerse Bump fok het my die heel aand gevat om die hele fred deur te lees kaptein ek wil net se jy het goeie werk gedoen....
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: El Zeffo on January 28, 2012, 07:49:45 am
Hey het jy nou n KLR? Ek dink baie aan my ou KLR
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: zetman on January 28, 2012, 08:44:22 am
ja ek het ˝ klr600 gekoop  besig om dit reg te maak gan kyk my fred in garage projecs
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Koot on June 12, 2012, 10:14:43 pm
Sheez,,,heelaand gelees, maar dit is 'n goeie thread!!! ;D ;D
Title: Re: KLR650 Restoration....Please help......and mods :)
Post by: Just In Time on June 14, 2012, 11:03:25 am
Another thread thats made me very unproductive - looking at all sorts of stuff on my KLR and found soo much that needs tinkering with.....