another broken doo - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 23 Old 10-23-2006, 11:23 AM Thread Starter
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Join Date: Oct 2006
Location: Corning, NY
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another broken doo

Well I opened up the case this morning, I don't have the parts yet, but they will be here this week. Loosened the adj bolt and the do just sort of flopped around, wouldn't maintain position, so at the least the springs are broken, if not the base to the doo. Now my issue is finding a rotor puller, I made one at work, but that rotor is really on there and I'm afraid I'm going to pull the threads off the bolt I made. I'll take a bunch of pictures.

2002 KLR 650
1978 RD 400 vintage racer
"I'm flat out like a lizard drinking"
Thanks Steve, you will be missed.
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post #2 of 23 Old 10-23-2006, 01:04 PM
 
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be sure to oil the threads of your puller...this is important on breaking it free

center punch the woodruff key later upon reinstall...this is a big help trick from eaglemike

BTW..our crew of 5 KLRs....2 out of 5 doos and or springs were broken...
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post #3 of 23 Old 10-23-2006, 01:36 PM Thread Starter
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I had to go over to the dealer and borrow a puller bolt, great guys over at" Ithaca recreation sports" anyways, I have no sign of springs that I can see yet, and the top of the doo is gone completely.


2002 KLR 650
1978 RD 400 vintage racer
"I'm flat out like a lizard drinking"
Thanks Steve, you will be missed.
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post #4 of 23 Old 10-23-2006, 03:25 PM
 
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:shock:

How many miles on it?
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post #5 of 23 Old 10-23-2006, 03:38 PM
 
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again I managed to fish the lost spring out from the oil pan with a magnet...the flexy one from ACE hardware works well...I use a large magnet first sometimes to drag the spring to near the drian plug hole..I have found the piece in the bottom front right dside of the oil pan...go get it...near the oil scrteen....THEN pull the oil screen while you are in there...and swap coolant out...and inspect water pump seal...I had to replace one at 22K miles on a 01 BTW...

good luck ..keep it up
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post #6 of 23 Old 10-23-2006, 04:09 PM
 
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Wonder if anyone will post saying it's photoshopped and an internet hoax? :roll:


Good catch, hopefully you'll find the broken parts and be better off soon!
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post #7 of 23 Old 10-23-2006, 06:25 PM Thread Starter
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Well I fished out the rest of the doo and the spring, it was in the rear section of the sump, I'm assuming under the tranny on the right side{ as you sit on the bike}. I managed to locate both the spring and the doo piece with a rare earth magnet from an rf generator I used to work on at another job. I had one hell of a time getting them to where I could get at it with a wand magnet. Let some asshat tell me I photoshopped these pics, With all the work involved getting that crap out I'd show him new uses for a wand magnet :mrgreen:

Here's the spring and the other doo parts.

2002 KLR 650
1978 RD 400 vintage racer
"I'm flat out like a lizard drinking"
Thanks Steve, you will be missed.
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post #8 of 23 Old 10-23-2006, 06:27 PM Thread Starter
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Quote:
Originally Posted by Airwolf
:shock:

How many miles on it?
didn't mean to ignore you, the beast has 14k on it. I think it broke several k ago though, just from the added vibrations I was feeling. Call me lucky.

I think at the least kaw should install a screen to keep the doo parts and spring from migrating to the sump and possibly trashing the tranny I'm off to the ntsb web site to file a report on the issue, all that have had to change theirs should do the same.

2002 KLR 650
1978 RD 400 vintage racer
"I'm flat out like a lizard drinking"
Thanks Steve, you will be missed.
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post #9 of 23 Old 10-23-2006, 06:28 PM
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Looks like that spring has been sprung! It's been where it shouldn't ought to be!

Glad you got'r fixed!

all the best,

Mike
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post #10 of 23 Old 10-23-2006, 06:31 PM Thread Starter
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and I'm looking forward to getting my new eagle mike doo any day now !

2002 KLR 650
1978 RD 400 vintage racer
"I'm flat out like a lizard drinking"
Thanks Steve, you will be missed.
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