93 flywheel 'coupler' cracked ? Is this a common thing? - 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 9 Old 01-25-2020, 08:14 PM Thread Starter
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Hey guys, was doing the doohickey on my new to me 93 klr650, all going well there, however I noticed that part of the flywheel/rotor appears to be cracked in a pretty bizarre way. I haven't been able to find any reference to this in my forum searches so I'm here to ask if anyone knows of this? The one interesting thing I found was while looking for replacement parts in eBay I found someone else's rotor that was cracked in the same exact spot. Anyone have insight?

Edit: trying to figure out how to include pictures, as this is obviously pointless without them.

Edit edit: https://m.imgur.com/a/GPmxma1




Last edited by Hobhayward; 01-25-2020 at 08:23 PM.
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post #2 of 9 Old 01-25-2020, 08:25 PM
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That is something that I have never heard of before, much less seen.

I have to admit to having taken only three sprag clutches off of rotors, though one of them I did several times.

Perhaps some of the others with more wrench time can weigh in. @pdwestman @Chuck_B @GreatWhiteNorth

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Sting like a butterfly.
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Last edited by Tom Schmitz; 01-25-2020 at 08:30 PM.
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post #3 of 9 Old 01-25-2020, 09:37 PM
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I have never / ever seen a sprag clutch race cracked before in 40+ years of twisting wrenches on these things.

A new part is about a $100.
https://www.rockymountainatvmc.com/oem-schematic/5

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post #4 of 9 Old 01-25-2020, 11:21 PM
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Quote:
Originally Posted by Tom Schmitz View Post
That is something that I have never heard of before, much less seen.

I have to admit to having taken only three sprag clutches off of rotors, though one of them I did several times.

Perhaps some of the others with more wrench time can weigh in. @pdwestman @Chuck_B @GreatWhiteNorth
I've not see that either. It's such a straight break it almost looks like it's cut or machined! I have 4 flywheels kicking around, just had a look, all of 'em solid, no crack lines like that.
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post #5 of 9 Old 01-26-2020, 10:41 AM Thread Starter
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Thanks guys, glad to know it wasn't just me. If I hadn't found the eBay picture I would have figured it was some crazy fluke, but I guess it still is 😂. It looks like they balance the flywheel but not sure if it's done as an assembly or just the part with the magnets. Think I might eBay an entire flywheel to keep it simple (and half the price of just the coupling).
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post #6 of 9 Old 01-26-2020, 11:34 AM
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The sprag clutch stuff, being a machined part, is naturally quite balanced.

The rotor is an amalgam of a drawn steel drum with magnets pasted inside and a timing bar tacked on the outside. It is not naturally balanced. It is manufactured by Denso and they do the drilling to balance the assembly.

I presume that KHI mate the rotor and the sprag rather than Denso.

I would not be afraid to buy only the sprag clutch bit if it were available.

Tom [email protected]

“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem
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post #7 of 9 Old 01-26-2020, 04:53 PM Thread Starter
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Well I found a guy with a parts bike in town and picked up his entire flywheel for $30, going to put that in. Apparently the top end was trash, is there anything to worry about there? I don't see any metal shavings or anything and it spins free/ locks as it should.
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post #8 of 9 Old 01-26-2020, 05:16 PM
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Examine the sprag clutch for metallic debris and look inside the rotor for the same. If it is clean, it's good.

Tom [email protected]

“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem
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post #9 of 9 Old 01-26-2020, 06:36 PM Thread Starter
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Ended up feeling a bit chonky in comparison to my flywheel, so I took his apart and think I'm just going to swap the bearing race in. His whole assembly has a lot more wear but the race appears ok. His clutch on the other hand is kinda ****ed up, the bottom side of the sheet metal guide is dented out from who knows what.

I would post the pics here but I'm on mobile and typing out the IMG code manually is a real pain. Pics are at this link though:
https://imgur.com/a/tQl8AGo

First is my cracked race, second is his race and third is the messed up clutch assy.
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