Nasty engine vibration on my '08 KLR 650 - Kawasaki KLR 650 Forum
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post #1 of 12 Old 04-01-2013, 10:51 PM Thread Starter
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Nasty engine vibration on my '08 KLR 650

Hey guys, just wanted to share what my buddy and I found on my '08, so, to make the story short, I bought this KLR from my neighbor about a month and a half ago, bike only had 4600 miles when I got it, had been sitting for years. After cleaning it up and getting a new battery, the bike ran great! forward 3 weeks, bike now has about 4750 miles on it and I start having a really nasty vibration any time I revved up above 1500 RPM, felt like my molars were gonna rattle off, and one of the failing bolts did come off
We first though it was the Doohickey, so we took the side covers off and found that the chain was nice and tight, the doo was intact but the stock spring was very loose, replaced both the spring and doo with aftermarket ones, put it back together and the bike ran nice and smooth, for about 20 miles, then on my way to work, it started vibrating badly again
Last weekend, my buddy ran into a post that stated a similar symptom on a 2008 KLR 650, and after months of debugging, turned out to be a broken gear on the left front counter balance sprocket, so, we decided to take my bike apart and check it, and sure enough, that's what it was, the sprocket was cracked all the way through, which allowed the counter balance weight to spin around, making the bike vibrate like crazy
Anyway, my replacement sprocket/balancer combo its on the way, hope to have it back together this coming weekend!
Here are some pics I took of the broken part and where it's located on the bike, just for reference
Enjoy!

-Jerry





The chain and other sprockets are lined up according to the specs, the counter balance weight is supposed to be pointing down, this one is turned about 45 degrees counterclockwise





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post #2 of 12 Old 04-01-2013, 11:19 PM
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Wow! That's a nasty break! Good thing you caught it before anything came apart! Thank you for the heads up, I've got an 08 as well!
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post #3 of 12 Old 04-01-2013, 11:33 PM
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woohoo thanks for the info on this, ill be sure to check mine if i start getting rattled

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post #4 of 12 Old 04-02-2013, 05:46 AM
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Good find, glad you found it.

Looking at the photos trying to figure out the cause it looks as though the broken sprocket was an interference fit over a boss machined onto the counterweight and when it cracked allowed the assembly to rotate out of position?

Is there a pin or key not seen that provides some kind of mechanical lock to that assembly?

The two holes seen in the rubber damper, did they go through the sprocket as well causing a weak point?

Sorry for all the questions, just gathering info for future reference.

Gray-haired riders donít get that way from pure luck.

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post #5 of 12 Old 04-02-2013, 07:42 AM
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Excellent find....I have never come across this yet, thanks for the information. Glad you got it fixed so to speak.

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post #6 of 12 Old 04-02-2013, 10:16 AM Thread Starter
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Hey guys, thanks for the replies!
And if your bike starts vibrating the way mine did, you will definitely notice it, my rear tire darn near bounced off the ground when the bike was idling around 2k RPM not fun

To answer Flash's questions:

Quote:
the broken sprocket was an interference fit over a boss machined onto the counterweight and when it cracked allowed the assembly to rotate out of position? Yes, the broken sprocket and the counterweight are pressed onto each other, and when the sprocket cracked, the weight was able to rotate freely, we put it on a vise and were able to easily move the sprocket with some pliers

Is there a pin or key not seen that provides some kind of mechanical lock to that assembly? There is no pin or any other lock that would keep these two pieces from rotating among themselves once the sprocket breaks, the pressed on force is the only thing keeping them together

The two holes seen in the rubber damper, did they go through the sprocket as well causing a weak point? This is a great point, and its the same thing I thought right when I saw the break, I didn't peel the rubber damper off to see if the holes went through, but I'm thinking they do, seems odd that the crack happened right at this point, I'll dissect the part when I get home today and update
I do hope this is not another "Achilles Heel" for the KLR, this is the 3rd one that I have heard off, all on the 2008 model, hope it was just a small, bad batch of sprockets...
Thanks again for the feedback!

-Jerry

Last edited by jerryv13; 04-02-2013 at 10:20 AM.
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post #7 of 12 Old 04-03-2013, 06:42 PM Thread Starter
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To update on the last question, yes, the two holes shown on the rubber also go through the sprocket as suspected, I would say this would definitely cause a weak point and that's where the crack happened...

-Jerry
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post #8 of 12 Old 04-03-2013, 07:17 PM
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Quote:
Originally Posted by jerryv13 View Post
To update on the last question, yes, the two holes shown on the rubber also go through the sprocket as suspected, I would say this would definitely cause a weak point and that's where the crack happened...

-Jerry
Thanks for checking. Good info. Will be looking at mine the next time in. Do you have the replacement? Is it the same?

I see no reason for them to be there other than to balance (un-balance) the assembly ???

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post #9 of 12 Old 04-04-2013, 12:16 PM Thread Starter
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I did buy a replacement part already, it's from a 2002 KLR, looked up the parts on bikebandit and found that they have the same part #, however, the pre-2008 balance weights look a tad different than the new ones, but the fitment should be the same, I'll know more if the part shows up tomorrow as it's supposed to
And you're correct, the only function of this piece of the puzzle is to balance the engine vibration, there's another similar balancer on the opposite end of the shaft this one is at, but that one doesn't look like it's pressed on a sprocket, no chains on the right side of the engine to that balancer!
Wish me luck, I hope to have the bike back together by Sunday night!

-Jerry
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post #10 of 12 Old 04-06-2013, 02:53 AM
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glad i read your post. did a quick search and found this one
http://www.twtex.com/forums/showthread.php?t=40884

looks like i have something else to inspect on my '08.

thanks for sharing.

b1pig
'07 Jeep JK-U Rubicon
'08 KLR 650
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