Hmmmmm. The KLR Malady - Wrist Twisters
 
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post #1 of 17 Old 02-24-2011, 05:33 PM Thread Starter
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Hmmmmm. The KLR Malady

Well, I pulled the right side cover off my motor today. Had to hunt down the idle noise. When I pulled the magnetic oil plug and looked, no metal junk.......so I had that going for me. When I pulled the case cover off, goodies sort of fell off their shafts and stuff, letting me know "Dude, you ain't done this before, have you?"

No big deal. There was one funny thing, however. It was a little hook of wire. Spring wire to be exact. Looks as if the KLR curse hit, but it hit soft. The spring holding the arm to the tensioner cam done busted and the little piece just sat in there waiting for me to spy it. It was nice enough not to get caught in the gears and reduce itself to debris.

Well, I don't have the right puller so looks as if I'll truck it on down to Danny and have him pull the magneto, the inner motor cover and get an eyeful of whatever else needs changing at 23,000 miles.

Who knows....maybe the cam chain tensioner and guide are shit. I don't know.

I wonder if he will take ammo or firearm service in partial trade.

Hmmmmmmmmmmmmmmm

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post #2 of 17 Old 02-24-2011, 05:37 PM
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So by "curse", I'm assuming it's a common problem? Is it the older KLR?

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post #3 of 17 Old 02-25-2011, 08:28 PM
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Sounds like the cam chain tensioner bug bit you huh?

If you were here, I would work for AMMO!

I Can and will ride anything!
Bikes I own:
New addition 1978 CB750Four
2006 919
1994 home built springer
1984 KLR 600
1953 Servi-car (I gotta get this put back together)
1942 WLA (Gotta finish this one as well)
1985 Honda 200M ATC
1985 Honda ATC 70
1997 Yamaha Big Bear 350 4X4 ATV
Early 1984 Ironhead Sporty (Wife has laid claim to this bike)
1986 Sporty that I am putting a ironhead engine into
YEA BIGDAA I Gotta GUN!
It's not that I am punishing YOU, I am just taking YOUR money and giving it to LAZY Asses who refuse to get off the TIT of the Government...Obama to Joe the Plumber
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post #4 of 17 Old 02-25-2011, 08:46 PM
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KLR "Doohickey" is the 2nd most popular googled term for the past 23 years.

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post #5 of 17 Old 02-26-2011, 02:30 AM
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I suffered through FOUR KLR's that all developed the "NOISE". Everybody said "thats just what they do"... on this 5th KLR I finally decided to do the doohickey change ,with the torsion spring, cause the guys on KLR650.net said it wud stop the noise. Best thing I ever did. The bike (an 09 with 3000 miles) started making the "noise" at 2500 miles and I was ready to sell it and be DONE with KLR's. Now the motor is totally different with a slight whirring sound. Best money I ever spent. My spring wasnt broken , but it was stretched. My dealer has a good KLR mechanic and he also did the "22 cent mod" to the carb. , so I got a grteat running, great sounding KLR. Good luck with yours

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post #6 of 17 Old 02-26-2011, 05:03 AM
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Quote:
Originally Posted by curiousmike View Post
KLR "Doohickey" is the 2nd most popular googled term for the past 23 years.
Was listening to the radio the other day and heard the term....fly like a G6.

Got home and typed in Google.......What's a...... and it completed the sentence with G6.

Apparently everyone else has wondered the same thing.....its an airplane.

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post #7 of 17 Old 02-26-2011, 06:40 AM Thread Starter
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Yes to everyone. The doohickey took a doo doo.
It's a 5 dollar spring that took the dump and now the cam in the balancer tensioner is backing off and letting stuff slop around noisily in the tower.

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post #8 of 17 Old 02-26-2011, 07:50 AM
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I've changed the Doohickey on 11-12 KLR's now, and 6-7 of them were found to have some part broken...whether it was just the spring, or whether the entire piece had shattered into several parts, all the bikes would run. I own one of the KLR's, and it's a bike I think I'll always keep. It really can do almost anything, although it does almost nothing great!

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post #9 of 17 Old 02-26-2011, 07:54 AM Thread Starter
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Quote:
Originally Posted by Blackheart View Post
I've changed the Doohickey on 11-12 KLR's now, and 6-7 of them were found to have some part broken...whether it was just the spring, or whether the entire piece had shattered into several parts, all the bikes would run. I own one of the KLR's, and it's a bike I think I'll always keep. It really can do almost anything, although it does almost nothing great!
So, what's needed to pull the magneto off????

“In my opinion, the M1 rifle is the greatest battle implement ever devised.”
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post #10 of 17 Old 02-26-2011, 08:18 AM
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There's 2 special tools you can buy from Eagle when you buy the parts. When you are done they sell QUICK on KLR.net...........but I just let my dealer do it cause he has the tools. It was a little over a hundred bucks to do the doo and the carb. mod and I didnt have to futz around with buying and selling tools . Quite often, on KLR.net, they will have a "group doo install" or loan tools to a member thats well known. Yadda yadda, but the site is pretty strict about selling rules and fees. Lotta trouble and cost to fix a problem that SHOULDNT EXIST. Happy Trail has a good "Install" section for the doohickey, too.

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post #11 of 17 Old 02-26-2011, 12:02 PM Thread Starter
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Just dropped the bike off at the shop.

“In my opinion, the M1 rifle is the greatest battle implement ever devised.”
General George S. Patton
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post #12 of 17 Old 02-26-2011, 12:32 PM
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Quote:
Originally Posted by Bigdaa View Post
So, what's needed to pull the magneto off????
It's a Rotor Puller bolt and wrench with a particular offset. I see you sent it to the shop to be done. The best spring is a Torsion-type, instead of the regular one with hooks on each end. A fellow by the name of Eagle Mike makes the best replacement balancer lever....aka "Doohickey".

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post #13 of 17 Old 02-28-2011, 09:21 AM
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I rode the KLR the other day, it made a racket, and locked the rear wheel at about 40 MPH clutch was immediatly grabbed and I released it and it fired back off and I went home.

Guess I got bit as well!

But it is the KLR 600 1984 with 19,800 miles of unknown abuse, hell I paid 50 bucks for it with a title!

Guess I will tear into it to probably find the cam chain followers broken or something.....

Mo Money!

I need some of that Obama money he has in his stash so I can fix it....

I Can and will ride anything!
Bikes I own:
New addition 1978 CB750Four
2006 919
1994 home built springer
1984 KLR 600
1953 Servi-car (I gotta get this put back together)
1942 WLA (Gotta finish this one as well)
1985 Honda 200M ATC
1985 Honda ATC 70
1997 Yamaha Big Bear 350 4X4 ATV
Early 1984 Ironhead Sporty (Wife has laid claim to this bike)
1986 Sporty that I am putting a ironhead engine into
YEA BIGDAA I Gotta GUN!
It's not that I am punishing YOU, I am just taking YOUR money and giving it to LAZY Asses who refuse to get off the TIT of the Government...Obama to Joe the Plumber
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post #14 of 17 Old 03-07-2011, 09:52 PM
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Interesting. Never knew those engines had that problem. I just thought they were bulletproof. I have a KLX650 and I know the auto tensioner can be a problem.

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post #15 of 17 Old 03-29-2011, 07:15 AM Thread Starter
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Update

I'm a little late on this so excuse me:

The bike is back home after its stint in the shop. $175 bucks. I have no problem with that.

Looks like not only the rinky dink spring was busted, the adjuster arm itself broke. This is a part that applies the force to the cam which swings the chain adjuster gear out to tighten the chain.

My mech says that the chain has half it's life left at 23,000 miles which I count as excellent for how hard I've pushed this bike. The bike sounds great with the whole mess adjusted properly. I've only driven it home so I've got some clean-up service to do on the old girl along with some periodic maintenance like new brake pads and chain degrease and service.

Riding time is here!

“In my opinion, the M1 rifle is the greatest battle implement ever devised.”
General George S. Patton
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post #16 of 17 Old 03-29-2011, 09:13 AM
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[QUOTE=I wonder if he will take ammo or firearm service in partial trade.
Hmmmmmmmmmmmmmmm[/QUOTE]

You an FFL? Where at?

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post #17 of 17 Old 03-29-2011, 09:54 AM Thread Starter
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Quote:
Originally Posted by petemacmahon View Post
You an FFL? Where at?
No I'm not. It's an inside joke.

“In my opinion, the M1 rifle is the greatest battle implement ever devised.”
General George S. Patton
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