My own tech day gone bad - Kawasaki KLR 650 Forum
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post #1 of 17 Old 05-22-2007, 02:30 PM Thread Starter
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Location: Salem Oregon
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My own tech day gone bad

Two weeks ago I found my self with a so-so weather Saturday and a doo kit and some other things I have been wanting to get done, so I declared my own tech day.

I started with the subframe upgrade kit, through drilled the frame and installed the new bolts. No problem.

I pulled the Doo, the factory one was showing a small bright spot (impending fracture??) on the weld at 5100 miles and the spring was broken and laying in the bottom of the case, and had been that way long enough that it had measurable wear through part of the finish on the spring. Installed the new machined billet part, followed all the instructions on Marknet, that site was written for people like me, very simple to follow.

I checked the valves and reset the idle mix screw out to 2.5 turns from the bottom, buttoned everything back up and lubed all the cables. I even did a cut out on the bash plate so I could reach the tensioner adjusting screw port without removing the pan.

Put everything back together and quite happy with myself refilled the oil and replaced the filter and hopped on to crank it over.

(KLUNK) sound of other shoe dropping! actually that is kind of the sound that the engine made when I tried to start it. it turned over about twice then made a seriously expensive sounding Klunk and was not budging from there. Now I can hand crank it arround about 3/4 turn in one direction to where it stops, then back the other way to the stop.

Anyone got any bright ideas on what may be the problem here? I have checked everyithing on the left side of the engine and will dive into the right side tonight.
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post #2 of 17 Old 05-22-2007, 04:43 PM
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My inital gut feeling is the key for the rotor fell out when you were putting it together. Did you take it all back apart afterward, or just pop the case and look?

Also - when you pulled the inner case, did you keep the lower shaft from pulling out when reefing on the inner case?

Joe
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post #3 of 17 Old 05-22-2007, 06:11 PM
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Sounds a lot like you got the washers mixed up when you put the big gear on for the starter. The one that goes on behind the flywheel.

Today is the first day of the rest of your life.
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post #4 of 17 Old 05-22-2007, 07:55 PM
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Behind the big starter gear are two thick spacers (they keep the gear off the cam chain). Between the rotor and the starter gear is a thin thrust washer that sometimes gets missed or mislocated.

The woodruff (halfmoon) key is troublesome if it isn't located correctly in its slot when you tightened down the rotor bolt. I've seen this be a problem twice.

Joe is right, too. The washer behind the idler gear often falls away unnoticed if you weren't careful when removing the inner engine cover. Usually, it falls into the oil sump and must be fished out with a magnet. If it or any other piece gets thrown into the gears, that's what we call "a bad thing."

Of course, your situation might be completely different.

Let us know how it turns out.

Life is a mortal adventure. Don't avoid all the risks.

2005 KLR650, ready for the world
1999 KLR650, badly in need of TLC...
1998 Honda Valkyrie Tourer
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post #5 of 17 Old 05-22-2007, 10:59 PM Thread Starter
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I appreciate your input, yup I manually checked that everything was clear when I reassembled and hand cranked the engine arround a couple times to make sure the starter gear cleared, had to pull it apart and file a little on the new doo just to make sure it cleared, I understand this is common.

so tonight I got home from work and started pulling bolts.....

I should change the name of this thread to "anyone got an engine for sale?"
it seems that in the process of manually cranking things arround to TDC to check the valves somehow I screwed something up. I ended up with a couple of "obstructions" in the piston that was causing the problem. Two exhaust valves to be specific! the head needs new valve seats on all 4 at least, the real issue is that when the engine went from cranking to critical stop it also either streched or compressed the rod/wrist pin/bearing or because with the head off I still have a hesitation at the bottom of the piston stroke. At the very least this engine gets a full rebuild this winter.

I am seriously looking for a new engine transmission to drop in so I can get riding, anyone got one for sale?
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post #6 of 17 Old 05-22-2007, 11:05 PM
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That sucks....

Time for the 688 upgrade (or whatever the new jug is...)

Joe
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post #7 of 17 Old 05-22-2007, 11:18 PM Thread Starter
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Angry

now the key is to find out what I did wrong and keep it from happening again or to anyone else. maybe it was just a good day for that engine to die. I kind of think that when I pulled things apart to do the do I may have slipped a link in the timing chain and got things out of mechanical time, but there is no mark on the piston that shows that the valves impacted then broke, it looks like they stress failed, anyway, I am just a machinist, not a mechanical engineer.

now I have two bikes that don't run,
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post #8 of 17 Old 05-23-2007, 06:47 AM
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You did a lot of things to the bike at once, (valves,doo,subframe) so it will be hard to pin point what went wrong. That makes a good case for just doing one thing at a time.
I'm really sorry about your situation, I know what its like to have a bike sitting there broke down during riding season.
E-Bay would be the best place to look for a motor,and you would come out ahead to by a complete bike, strip the parts you want off it, and then sell the rest on E-Bay. I have done that a couple times. The really bright side about doing that is you get to tear one apart and not worry about putting it back together.

Today is the first day of the rest of your life.
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post #9 of 17 Old 05-23-2007, 08:54 AM Thread Starter
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At least I can wax philosophical about it, the Doo spring was an inpending failure and the doo was probably going to go as well. At least this happened in the shop and not out on the road, in the middle of nowhere, in the rain, with no cell service. All things considered, I feel lucky.
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post #10 of 17 Old 05-23-2007, 02:11 PM
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Hmmmm..am getting me worried about doing the doo myself now!! But the dealer sure isn't gonna help me out with it, so will suck it up, do it very slowly and one step at a time. Cross fingers nothing goes kerchunk when all is finished. Man I am truly sorry to hear about your mishap, but as you said, better in the shop than a possible lock up at highway speeds. Keep us posted on what you find out and how it goes.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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