Missing something - 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 12 Old 03-10-2019, 02:50 PM Thread Starter
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Question Missing something

Today i was taking a look at the wires that connect to the stator they are ruined from the elements and the gasket didnt look too good. Long story short when i took the side case off i noticed there were two "gears" that could fall off so to avoid damage i sat them aside. Now putting it back together. Im not the best mechanic but i feel like ive dropped or lost a "spacer/washer"( for lack of knowing what it is) the one gear has two spacers on either side of the gear holding, the other had only one and the "bearing"(idk what it is, looks like a long bearing of some kind) was loose and would slide out or fall out of the gear unlike the other gear. ive looked through my manual suplement and cant find anything to give me an idea of what im looking at. And ill post a picture later when i figure out how to narrow it down cause i know how hard it would be to identify without one. i love trying to fix one problem then making several more. Thanks in advance!
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post #2 of 12 Old 03-10-2019, 05:09 PM
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Here are Tom’s videos on the doohickey replacement which happens on the same side of the engine. About 8.5 minutes into the first video he explains the gears and washer situation. From your description it does sound like you dropped a washer which you will have to retrieve. The bearings aren’t an issue. Just put them back in the gear. I think your questions are answered in the first video.

If you are lucky the washer may just be stuck onto the back of the gear with oil. Check that first.




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Last edited by klr4evr; 03-10-2019 at 05:13 PM.
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post #3 of 12 Old 03-11-2019, 11:18 AM
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Did you find all four of your thrust washers, Thomas? 1 thrust washer on each side of each gear only.

pdwestman
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post #4 of 12 Old 03-11-2019, 01:19 PM Thread Starter
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Ill have to look again, the one had two and the other one had only one but the idea just came to mind if maybe its stuck to the magnet. but if i cant find it can anyone point me to a replacement? thank you for identifying my missing item too! headed to google for trust washers. Btw i just noticed the "key ring" i got with the bike is most definitely a doohickey so imwondering if its been replaced and someone misplaced the thrust washer putting everything back. I will let you guys know of my findings
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post #5 of 12 Old 03-11-2019, 01:39 PM
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92022-1649 washers, qty 4

https://www.kawasakipartshouse.com/o.../starter-motor

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post #6 of 12 Old 03-11-2019, 01:46 PM Thread Starter
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Thank you!
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post #7 of 12 Old 03-12-2019, 08:58 PM
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It is easy for any of those four thrust washers to stick to the engine covers right where the shaft they are on goes into the cover. They are so thin that with a little oil on them it is hard to notice them stuck to the covers even when you are looking for them. Look closely. On reassembly make sure there is one and only one on each side of each gear pair.

If you have lost one, get the factory replacement part as recommended by pdwestman. A hardware store washer will not work.

Last edited by GoMotor; 03-12-2019 at 09:04 PM.
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post #8 of 12 Old 03-12-2019, 10:04 PM
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Just last week I had one fall off as I was removing the stator cover. It lodged itself between the case and the stator.

Tom [email protected]

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Last edited by klr4evr; 03-13-2019 at 06:11 PM. Reason: Typo
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post #9 of 12 Old 03-13-2019, 06:25 PM
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I am trying to identify a part but i can only identify it with the color of the wires which are red and blue black and yellow red and yellow. If you can help me identify this part that would be great. thanks in advance.
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post #10 of 12 Old 03-13-2019, 06:52 PM
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Go to that parts screen which was provided earlier and click on the LIME GREEN "Motorcycle" above the Black "2006 Kawasaki KLR650" starter motor to go to the index.
Find your year & your model, find the necessary parts screen.

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