The Sticking tripmeter issue - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

  • 1 Post By GreenWenonah
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post #1 of 8 Old 07-09-2014, 03:33 PM Thread Starter
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Join Date: Jul 2011
Location: Napa, Ca
Posts: 659
The Sticking tripmeter issue

The first time I did this, I fixed it myself with some mods at around 13,000 miles. Now I have over 36,000 miles and it started doing it again. Since most of us use this as a fuel gauge, it's worth it. This second time though, there was a lot of dust in there from all of my off road riding, so clean it out.

You really need compressed air to do this, or a couple of cans of that keyboard cleaner.

1. Remove the front fairing and set aside.

2. Remove the cluster from the frame mounts with three screws going thru rubber mounts. Disconnect the speedo cable. Get a place to work on it.

3. Remove the front bezel from the cluster.

4. Remove all the screws on the wires going to the gauges, the two screws holding the speedometer in, now lift the face with gauges out of the cluster housing.

5. Hold the back of the speedometer, push the reset rod and see how it works, and see where it is sticking. There will likely be a sharp edge on the plastic lever that gets pushed by the plastic plate.

6. Using a Dremel Tool or file/sand paper/Exacto knife/razor blade/whatever you have, grind down the edge to a radius. Clean off the filings!

7. I used silicone spray to lube the trip number wheels on the shaft, but use some sort of dry lube, then blow off the excess.

8. Lube the contact points of the lever & plate with a silicone lube, or light grease.

9. TEST IT!!!! Make sure that it resets easy a couple of times by releasing the lock and rotating the number wheels. Lift the lever you ground off halfway and that should release the numbers, and then use a small screw driver to rotate them.

10. Clean the face of the speedo off with a soft cloth.
11. Reassemble everything and take it for a test ride.

I added some stupid farlkes to my speedo face. I should have put the wobbles at 85 though.

Hope it helps, and see you out on the trails.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California

Last edited by campfire; 07-26-2014 at 02:35 PM.
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post #2 of 8 Old 07-09-2014, 07:06 PM
Join Date: Jan 2011
Location: NW MO
Posts: 5,344
Nice writeup, campfire. Thanks. Just as you said, it's not just a tripmeter, it's a gas gauge. I call for permanent enshrinement in the "Common Mods And Issues" thread.

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post #3 of 8 Old 07-09-2014, 08:45 PM
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Location: Redondo Beach
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I agree, a very nice job campfire!

It's been added.


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post #4 of 8 Old 07-10-2014, 03:48 AM
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Join Date: Apr 2012
Location: Cairns, Australia.
Posts: 191
Thanks for taking the time to photograph and document the process. I don't have a problem with mine but I'll now know where to look if I do.
Well done!

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post #5 of 8 Old 07-10-2014, 05:14 AM
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Join Date: Jul 2012
Location: GA.
Posts: 132
Excellent info and write up campfire! Thanks
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post #6 of 8 Old 07-10-2014, 09:49 PM
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Join Date: Oct 2008
Location: Toronto Ontario
Posts: 72
Mine crapped out a few weeks ago at 98,000 kilometers. An easy fix thanks to this great write up and pics.

2008 KLR 650 (108,000 kilometers and rising)
1987 K100RS
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post #7 of 8 Old 07-21-2017, 07:09 PM
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Join Date: Jul 2017
Location: Puget Sound
Posts: 4
New cam

Attack of the Zombie thread.

I got too ambitious polishing and ate away too much of the lever. Instead, I made a replacement cam out of copper sheet with a longer lever. I polished the contact surface very well before lubing with Teflon spray. Works great now. Snapped a picture but I don't think I can link yet.

campfire likes this.

Last edited by Tom Schmitz; 07-21-2017 at 07:59 PM. Reason: Hosted the picture on flickr rather than the dreaded Google
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post #8 of 8 Old 07-22-2017, 04:55 PM Thread Starter
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Join Date: Jul 2011
Location: Napa, Ca
Posts: 659
Excellent idea!
I have a chunk of aluminum sitting here that I'm saving if that thing ever goes out again after seeing your post. Thanks.

Cracked over 54,000 miles this summer on trips and it's still working good.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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