Dag Nabbit!! - 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 10 Old 12-14-2014, 06:08 PM Thread Starter
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Dag Nabbit!!

So, I'm getting to know this new to me '07. What I am learning is that although there is only 5600 miles on this bike, that means it sat a lot. No real harm that I can tell, other than some stubborn fasteners. My guess would be that it was under cover, but not in a temp controlled environment.

So far , I've changed oil and filter, cleaned and re-oiled the air filter, changed out the coolant along with a Thermobob2 install, checked the front wheel bearings and axle, lubed all the cables, and changed out the rear brake fluid.

Which brings me to the "dag nabbit". The reservoir cap screws on the front brake are cute little buggers that maybe have never been out. One came out with a serious twist. The other one, the screwdriver slipped and rounded out the head...badly, after repeated attempts. I shot some PB Blaster to it, and it's sat for a while. Now it's time to attack. Any thoughts on getting that screw out without destroying parts? slot it with a dremel?.....a tiny easy-out? Also, a new reservoir cap after I mess this one up is a possibility. There is no Kawasaki dealer close........what's a good source for o.e.m. parts? Thanks, John

btw, if there's a thread on this, I apologize.

John
'07..The red and silver one. (they go faster)

Last edited by Johnny Gypo; 12-14-2014 at 06:33 PM.
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post #2 of 10 Old 12-14-2014, 09:00 PM Thread Starter
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I got that screw out. Just tapped in a tad bigger phillips screwdriver, kind of making a new head in the soft metal. Gotta love PB Blaster.

John
'07..The red and silver one. (they go faster)
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post #3 of 10 Old 12-14-2014, 10:39 PM
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Good deal! Many people replace those screws with allen head screws.
jj

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post #4 of 10 Old 12-15-2014, 09:03 AM
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post #5 of 10 Old 12-15-2014, 11:21 AM Thread Starter
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Thanks guys. I was going to look at our local Ace, a good supply of metric screws and such, but I figured I might have a hard time finding something with a cone AND allen head. I need to order a doohickey anyway. One thing about this KLR stuff......it's gobs cheaper than sitting around all winter throwing money at my Harleys! I'm likin' it.

John
'07..The red and silver one. (they go faster)
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post #6 of 10 Old 12-15-2014, 12:18 PM
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A dab of anti-seize is a good plan for those screws. FWIW, if I can discourage you from using stainless (soft as butter) in there, please be discouraged. ;-)
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post #7 of 10 Old 12-15-2014, 01:48 PM Thread Starter
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Quote:
Originally Posted by Normk View Post
A dab of anti-seize is a good plan for those screws. FWIW, if I can discourage you from using stainless (soft as butter) in there, please be discouraged. ;-)

Gotcha. Thanks!

John
'07..The red and silver one. (they go faster)
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post #8 of 10 Old 12-15-2014, 07:10 PM
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Those "Phillips looking" screws are actually JIS Screws and aren't
completely compatible with a Phillips screwdriver.

See. http://www.instructables.com/id/When...rial-Standard/
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post #9 of 10 Old 12-15-2014, 07:46 PM
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Correct + JIS "Phillips" are not a cam-out design to the degree of the true Phillips. I usually "correct"mine with an anti-cam out Phillips bit and perhaps a seating tap with a 4 oz gasket hammer.

Quote:
Originally Posted by EXBMW View Post
Those "Phillips looking" screws are actually JIS Screws and aren't
completely compatible with a Phillips screwdriver.

See. http://www.instructables.com/id/When...rial-Standard/
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post #10 of 10 Old 12-15-2014, 08:36 PM Thread Starter
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Wow. Interesting. The whole metric thing is, at least as far as motorcycles go, somewhat different than I am used to, But, I'm learning and appreciate the feedback. I'd never heard of JIS screw heads, and found that link interesting, thanks ex.

Anyway, I found some exact screws, except with an allen head down at the local Ace today. I don't know if all Ace stores have as dynamite nut and bolt section as the one in East Wenatchee Wa., but it is darn complete. I got home and Mighty Vac'd my front brake line and got some yukky lookin' stuff out, put in new DOT4, a little antiseize on the screws, and now both ends are done. Thanks again for the input!

John
'07..The red and silver one. (they go faster)
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