Engine Vibration @ 5,000 RPM - 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 14 Old 02-05-2007, 01:12 AM Thread Starter
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Engine Vibration @ 5,000 RPM

The morning I left for the Petaluma Tech Day my engine started a significant vibration. Tightened everything at the TD and it did not go away. Since then I have been removing parts to see what would make it go away, NOT! Saturday I thought I found it but I was wrong. I went to start my KLR and the ignition switch slid into the dash. Yahoo I found it, wrong! I did find the vibration loosened the iginition switch bolts enough to where they fell out. When I grabbed the switch the vibration did not change. At Redding Tech Day I had a problem with the Cam Chain Tensioner (CCT) so I am thinking that could be the problem. Tonight I removed the CCT to see what it looked like. The CCT was fully extended. Is this noraml for an engine with almost 12K miles. It feels like I am looking for the Needle in the Hay Stack. Any suggestions will be appreciated. I hate to but it is parked in the garage until I find the vibrating gremlin. I will ride my bicycle to work and back and S10 to the grocery store. Thanks.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #2 of 14 Old 02-05-2007, 04:26 AM
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cct shouldn't be fully extended. might have stretched the cam chain when it jumped on you. there is a chance that the balancer chain jumped at the same time giving you the vibration. better open her up for a look see.
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post #3 of 14 Old 02-07-2007, 01:03 AM Thread Starter
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I did remove the CCT incorrectly. Tonight I removed it correctly and found I had 3mm or 3 notches left. I reinstalled the CCT, ran the engine, removed the CCT and found the same 3mm or 3 notches.

There are 17mm or 17 notches of travel for the CCT. What would be a normal measurement? Is 3mm or 3 notches not good?

Could the Guide-Chain,RR(rear) (12053A) be worn or damaged?

I am looking at the Kawasaki diagram. I can see how the Guide-Chain,FR(front) (12053B) functions (same as Guide-Chain,RR) as well as Guide-Chain,LWR. What are these parts made of? Can they be damaged or wear out?

Replacing the parts and/or the Cam Chain if needed are not a problem though I don't want to do it if they aren't damaged or broken. If I remove the left-side what should I for. Is there a way to measure the wear?

If needed does anyone have good parts for sale at a decent price? PM me if you do.

It is supposed to rain starting Wdenesday and ending Monday so this might be good timing for this repair/project.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #4 of 14 Old 02-07-2007, 03:01 AM
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the chain guides aren't going to wear out. they look fine in my 27,000 mile explode-a-pop motor. i don't remember anybody suggesting to check that the balancer stayed in time when you jumped time in redding. i'd look at the balancer timing in relation to the cam timing before anything else.
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post #5 of 14 Old 02-08-2007, 11:08 PM Thread Starter
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I have decided to check the valve clearances; check the cams for wear; check the cam chain stretch; remove the left-side and check the Cam Chain Guides for wear; replace the Balancer Lever spring with a new Eagle spring; and put it back together and listen for a difference. If the vibration is still there I will return to the Forums for your opinions. Thanks for everyones help.

I will need to borrow a set of Doohickey tools and i might be able to get a set at the Tech Day this Saturday.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #6 of 14 Old 02-16-2007, 12:15 PM
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My KLR has had a vibration that also started at around 12,000 miles. I now have 15,000 on it. It hasn't gotten any better or worse. I just ignore it now.

The shortest distance between two points is a damn shame.......

I rode Broke Back mountain, and my a$$ is killing me.....
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post #7 of 14 Old 02-16-2007, 12:26 PM Thread Starter
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Quote:
Originally Posted by KLRGunn
My KLR has had a vibration that also started at around 12,000 miles. I now have 15,000 on it. It hasn't gotten any better or worse. I just ignore it now.
Would you ignore it if it vibrated the ignition switch bolts until they disappeared?

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #8 of 14 Old 02-18-2007, 11:35 PM Thread Starter
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To make a long story short...there is a neighbor that is no longer welcome in my garage.

I am pulling the head because the intake valves are bent. Tomorrow I will contact http://www.schnitzracing.com/ (Cary) and make plans to ship them my head (KLR) for the repairs. After it is returned I will continue to search for the vibration. By the time I get the head back I will have replaced the drive chain and sprockets, upgraded the dash lights to LED, replaced the electrics with three of Tammy's kits, and cleaned the rest of the KLR.

HELP! I am trying to remove the two 12mm crown nuts on the lower side of the head. What is the best tool to use remove these bolts in the tight quarters? I don't have a stubby set of metric wrenches but is that is what it takes I will go to Sears tomorrow.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #9 of 14 Old 02-19-2007, 04:23 AM
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Quote:
Originally Posted by tomatocity
HELP! I am trying to remove the two 12mm crown nuts on the lower side of the head. What is the best tool to use remove these bolts in the tight quarters? I don't have a stubby set of metric wrenches but is that is what it takes I will go to Sears tomorrow.
if i remember correctly it's super easy to get to those with the starter out of the way.
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post #10 of 14 Old 02-19-2007, 11:17 AM
 
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I would like information on the LED dash lights and the electrics you plan to replace with Tammy?s kits. Pictures would be great!
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