Stuck Rotor / Doohickey - 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 24 Old 02-12-2009, 12:34 AM Thread Starter
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Stuck Rotor / Doohickey

I dropped my 06 off at the local Kawi dealer to get the doohickey replaced. They called with the bad news. The rotor is frozen and will not come off. They have never seen this before. They called Kawasaki corporate who had no ideas other than using the correct puller, trying heat etc. which had already been done. Bottom line, the bill is going from $200.00 to over $800.00 as the rotor has to be cut off and a new one installed.

Neither the dealer or the factory had ever heard of this. Anyone here had this happen?
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post #2 of 24 Old 02-12-2009, 01:16 AM
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I've dealt with a few of these long distance. A couple of things affect this. If the first puller used is not a good one it can damage the threads. As soon as this happens, it's a problem. There's only about 4 threads in the rotor for the puller to grab. There is another way to pull the rotor. Make a plate with holes that match the holes in the bottom of the rotor, the 6 botls that hold the starter drive clutch to the back of the rotor. Put longer threads in this plate, and use the 6 8mm bolts to attach this plate to the rotor.

I can save you some money since your bike is a 2006. I have a few spare rotors from donor engines, so give me a call. I buy engines and part them out to help people - parts are usually free. (to others than the original poster, please don't call unless it's a disaster like this one, ok? )

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all the best,
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post #3 of 24 Old 02-12-2009, 09:08 AM Thread Starter
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Mike,
Thanks for the response and the offer of the used rotor. I am going to print your suggestion and fax to the dealer where the bike is located. I don't know if they started cutting yet or not. Hopefully with your suggestion for making a plate, the original part can be spared from destruction.

Kirk
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post #4 of 24 Old 02-12-2009, 10:32 AM
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I was going to say, another guy here had the same problem and had to cut his rotor off using cutting saw and chisels. Once off the replacement rotor went on without issue. Sorry you had this problem.

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post #5 of 24 Old 02-12-2009, 06:29 PM
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Damn.... I was thinking of having my local K Dealer take care of my doo, but now im bitting my nails. Sucks man, hope you get it taken care of!

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post #6 of 24 Old 02-12-2009, 07:51 PM
 
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What can cause one rotor to stick like that but others not? I did my Doo yesterday, Followed Mike's instructions (eastcoast website) watched the whole process on youtube about a hundred times and mine went without a hitch. I was sweating bullets the WHOLE time because of storys like this one. It makes me nervious to hold a tech day and help anybody because I don't want somebody blaming me for their bike because of this kind of stuff. Mike you've done a ton. What's the most common hang up?
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post #7 of 24 Old 02-12-2009, 10:24 PM
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I always use a breaker bar with the puller. The harder it's stuck, the slower I go. Quality of the pullers varies greatly. That's one reason I started making them years ago. I also use grease on the end of the puller and the threads.

A couple of other things to pay attention to: watch for the small thrust washers on the starter gears. Keep the idler shaft (the shaft the lever/doo fits onto) pressed into the engine cases as you remove the inner generator cover. That's the inner cover that gets removed to get to the old spring. Keepng the shaft pressed in prevents the thrust washer behind the dler sprocket from dropping. You don't want to unknowingly drop the washer. If you drop, it's pretty easy to put back into place. Just don't drop it and not know it.

Be sure to put the gasket where it should be. I know what sounds simple, but..... Sometimes people tackle stuff like this with zero or little wrenching experience.

all the best,
Mike

Last edited by eaglemike1; 02-13-2009 at 10:25 AM. Reason: typo
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post #8 of 24 Old 02-13-2009, 10:00 AM
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Quote:
Originally Posted by DUBL-A View Post
Damn.... I was thinking of having my local K Dealer take care of my doo, but now im bitting my nails. Sucks man, hope you get it taken care of!
I wouldn't let an isolated event scare you. If you live in fear you won't leave your bed. Why aren't you doing the job yourself?

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post #9 of 24 Old 02-13-2009, 11:15 AM
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Quote:
Originally Posted by tzuk95 View Post
What can cause one rotor to stick like that but others not?
Probably over torqued from the factory. We had a tough one on an '08 at the last techday in Plumas Lake.

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post #10 of 24 Old 02-13-2009, 03:28 PM
 
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Tapers are funny things. Sometimes they need to be shocked to break them loose. If it doesn't come loose right away, smack the end of the puller screw while it's still tightened. Use a brass or lead hammer. I use EP grease to lube the screw also.
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