Metal in the oil filter - 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 6 Old 12-04-2014, 06:03 PM Thread Starter
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Metal in the oil filter

Hey guys,
My first post here, so please have some patience.
I'm a traveler doing Central and South amerika on a 2003 KLR650 I bought two weeks ago. It has 26000 miles and works fine.
However, changing the oil I found fine, fine particles of metal. I'm pretty sure most of it is Aluminium, but there are also some black, small particles there. I cleaned the oil filter and rode another 500 miles. I checked the filter again and found fresh metal.
The bike runs fine, whithout any distinct, obviously wrong noices. I can sometimes hear a very weak ratteling noice from what I think is the transmision, but it's so weak and not always there, so it's hard to tell. Clutching sometimes help on the sound, but not necesarily instantly. I also sometimes hit neutral when trying to change gear from for example 4th to 3rd.
The last owner changed the sylinder from a 650 to 685. I have no idea why, but as I said the motor seems to work fine.
I don't know if any of this is of any importance, I just try to give you as much to go on as possible.

I have pictures of the oil filter with metal in it, they can be sent upon request.

Thanks and cheers from Costa Rica,
Sigurd
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post #2 of 6 Old 12-04-2014, 06:31 PM
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Hello and welcome to the forum!
It's pretty common to have trace amounts of particles in your filter when the bike is new, but usually it stops after the first change or so. Not sure why you would still be getting filings with that many miles, I'm thinking something is not right. Hoping someone else will chime in and give you some suggestions...

Sounds like an awesome trip though, I'm envious! Ride safe

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post #3 of 6 Old 12-04-2014, 06:48 PM
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The most common cause is a loose balancer chain hitting the case up by the upper balancer bearing.

This is nygee1981's picture:



The easiest way to check that is to remove the left side cover, loosen the balancer adjusting bolt, and see if the lever can be tightened by hand by pushing it towards the front of the bike with a screwdriver. If it can, tighten the bolt, reinstall the cover and ride on. Fix properly at the first opportunity.

Tom

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On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again. -Philip Marlowe

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post #4 of 6 Old 12-04-2014, 10:41 PM
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Stuff from the clutch pack too?
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post #5 of 6 Old 12-09-2014, 10:27 AM Thread Starter
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Tom Schmitz were right - Broken Doohickey

Tom Schmitz were right.
The doohickey which tightens the chan was broken and it looked excactly like the picture above.
At the moment I have to problems, writing them here for other fresh KLR owners to learn:
First of all, Im in Panama City and have a really hard time finding the part here. I will have to order it and this will either take a long time or be expensive. Order the Eagle doohickey, its the same price and way stronger.
Second, the broken part of the doohickey and the spring helping thightening it is still inside the engine. Its a PIA to get it out and I have still not figured out how to do it.
Also, If you just have to tighten the chain this is something you can do on your own. If the doohickey is broken, though, you need special tools to open and get access. Therfore, if you think you have this problem be close to a dealer/mechanic if you want to try fixing this on your own. Its stupid to have to drain the oil, check, put it back together, add new oil and drive for 20 mins before draining it again.

Thanks for the answers, I appreciate it.
Sigurd
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post #6 of 6 Old 12-09-2014, 12:12 PM
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Sigurd -

Take a look at post #8 in this thread. We had a bit of a discussion on where doohickey parts are most likely to land. Your best bet to retrieve the parts is, first, in the outer case where they may be laying about and, second, fishing a flexible magnet through the oddly shaped hole in the crank case.

For a fix in the bush, where parts may not be readily available, a stock doohickey and spring is better than none at all. So much the better if you can source a second generation ('08+) lever.

As to a method to get the rotor off, try the suggestions in this post. As well, a semi-truck shop may have a wrench you can use to hold the rotor.

Remember, in the bush (Costa Rica qualifies) the objective is to get yourself underway once again, the better to have adventure, wine, women and song. Once you get to your destination you can either fix the beast, push it over a cliff or leave it for the natives' benefit.

Best of luck,

Tom

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On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 12-09-2014 at 12:14 PM.
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