Speedometer Kaput... - 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.

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post #1 of 10 Old 11-25-2016, 03:07 PM Thread Starter
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Speedometer Kaput...

While out riding my '09 KLR this morning, I thought I heard some squeaking coming from the front wheel area when coming to a stop from a long highway run. Before I could stop to diagnose, the speedometer and odometer stopped working, after that no more squeaking. I'm assuming I either broke a cable or the front wheel speedometer drive failed. Had to use the tach and my "butt dyno" to guess my speed and mileage for the rest of the ride.

I'm not sure what drives the speedometer cable in the front wheel hub, but I'm guessing a gear of some kind.

I'll probably pull it apart tomorrow to look but does anyone else have experience with this?

Thanks in advance for the help.

John "JohnBG' Grocke

2009 KLR 650
2006 Ural Raven (Patrol) 2WD

Love is the feeling you get when you like something as much as your motorcycle. ― Hunter S. Thompson
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post #2 of 10 Old 11-25-2016, 08:43 PM
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The speedo cable broke on my 08 at around 5000 km's. Little to no factory lube in it, so when I bought my replacement I lubed the heck out of it before installing it. If I recall, it was a pretty easy install, though getting it screwed onto the bottom of the speedo was a bit of a knuckle scraper if I'm remembering right.

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post #3 of 10 Old 11-25-2016, 10:15 PM
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Front wheel removed/replaced recently?

A common cause of speedometer failure remains: Bent tabs on the speedometer drive "washer" in the hub. Unless these tabs engage their respective slots, no speedometer cable rotation.

The common cause of bent tabs is incorrect front hub assembly.

Corrective action: Flatten washer tabs; re-assemble hub with tabs in their slots.

Reference # 41084, Front Hub: https://www.kawasaki.com/Parts/Parts.../2009/KL650E9F

"Receiver-Speedometer"

Last edited by Damocles; 11-25-2016 at 10:23 PM.
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post #4 of 10 Old 11-26-2016, 07:40 AM
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On two different occaisions, my speedo cable has unscrewed itself from the back of the gauge. After the second time, I reconnected it using blue locktite. It has stayed put ever since then.
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post #5 of 10 Old 11-27-2016, 03:13 PM
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First and easiest check is to unscrew the knurl nut on the end of the cable sheath down near the hub and pull it back a couple of inches to reveal the drive cable inside. Make sure the cable the cable is pressed down into the hub fitting and rotate the wheel an half turn or so to see if the drive cable turns while you squeeze the cable to add a little friction to it. If the cable turns, the drive mechanism in the hub is good. If not, you will have to remove the wheel and fix the mechanism as mentioned above.

Also, you can pull the cable out of the sheath to make sure it is not broken. When reinstalling the cable in the sheath it helps to rotate it a bit to help the square end line up with the square hole in the speedometer. For the same reason, rotate the wheel a bit if the cable doesn't slip fully into the fitting at the hub.

If this doesn't reveal the problem, you will need to get to the back of the speedometer to check the cable connection there.

Last edited by GoMotor; 11-27-2016 at 03:15 PM.
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post #6 of 10 Old 11-27-2016, 05:18 PM Thread Starter
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Quote:
Originally Posted by Damocles View Post
Front wheel removed/replaced recently?

A common cause of speedometer failure remains: Bent tabs on the speedometer drive "washer" in the hub. Unless these tabs engage their respective slots, no speedometer cable rotation.

The common cause of bent tabs is incorrect front hub assembly.

Corrective action: Flatten washer tabs; re-assemble hub with tabs in their slots.

Reference # 41084, Front Hub: https://www.kawasaki.com/Parts/Parts.../2009/KL650E9F

"Receiver-Speedometer"
I bought the bike about 8 months ago and haven't removed the front wheel. Tire is getting worn so I might guessing it's been a while since the wheel has been removed. I've got a set of tires to install while I got it apart. Bioengineered has almost 59,000 miles on it if that makes any difference.

John "JohnBG' Grocke

2009 KLR 650
2006 Ural Raven (Patrol) 2WD

Love is the feeling you get when you like something as much as your motorcycle. ― Hunter S. Thompson
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post #7 of 10 Old 11-27-2016, 05:22 PM Thread Starter
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Quote:
Originally Posted by clogan View Post
On two different occaisions, my speedo cable has unscrewed itself from the back of the gauge. After the second time, I reconnected it using blue locktite. It has stayed put ever since then.
There's was definitely a noise from the front wheel area that happened just before the speedometer stopped working. I'm doubting it was from the back of the speedo but will check.

John "JohnBG' Grocke

2009 KLR 650
2006 Ural Raven (Patrol) 2WD

Love is the feeling you get when you like something as much as your motorcycle. ― Hunter S. Thompson
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post #8 of 10 Old 11-29-2016, 08:50 PM
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Quote:
Originally Posted by JohnBG View Post
There's was definitely a noise from the front wheel area that happened just before the speedometer stopped working. I'm doubting it was from the back of the speedo but will check.
Mine broke right at the bottom where the cable went into the hub. Not sure if it made a noise when it went though... Betting that's what's wrong with yours.

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post #9 of 10 Old 02-12-2017, 11:21 AM
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Quote:
Originally Posted by Damocles View Post
Front wheel removed/replaced recently?

A common cause of speedometer failure remains: Bent tabs on the speedometer drive "washer" in the hub. Unless these tabs engage their respective slots, no speedometer cable rotation.

The common cause of bent tabs is incorrect front hub assembly.

Corrective action: Flatten washer tabs; re-assemble hub with tabs in their slots.

Reference # 41084, Front Hub: https://www.kawasaki.com/Parts/Parts.../2009/KL650E9F

"Receiver-Speedometer"
I just had this exact situation. However, the wheel had not been removed recently. I took delivery of my 2016 KLR650 with a set of Conti TKC80s on November 27, 2015. While I've changed the rear twice (and it is getting desperate for a third) the front is the same tire as when I took delivery. Earlier this week the speedometer started to go wonky then it just went dead (along with the odo and trip). So I pulled the wheel off and then the speedo housing and, sure enough, the drive washer was the problem. When the dealer installed the wheel they didn't get the outer grooves lined up in the slots on the hub and when they torqued the axle bolt they caused the drive washer literally to cup inward. It must have been torqued so tightly that the friction alone kept it in place for over 14 months. Same corrective action, I flattened the washer, reinstalled it correctly and all is now well. However, I think this case may indicate that the drive washer may still be the issue even if the wheel removal was a long time ago.
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post #10 of 10 Old 02-12-2017, 12:21 PM
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Quote:
Originally Posted by Bill10 View Post
I just had this exact situation. However, the wheel had not been removed recently. .......................It must have been torqued so tightly that the friction alone kept it in place for over 14 months. Same corrective action, I flattened the washer, reinstalled it correctly and all is now well. However, I think this case may indicate that the drive washer may still be the issue even if the wheel removal was a long time ago.
Yes, it can be many miles later before the problem becomes obvious. I on a long trip, I had a front tire replaced in Bozeman, MT. I wanted to watch the kid that sweeps the floor change the tire, but "No, Because of Insurance". About 900 miles later the speedometer stopped working.

At that time I was still on the trip and unaware of the "bent tab" problem, so I put a $15 bicycle speedometer on and continued on with my trip. Latter while installing a new tire, I saw that the bent tab had been grinding away at the hub until there was no notch left. New hubs are expensive, so I installed a Trail Tech digital unit.

Now, I install tire my self or insist on observing.

I have since learned that it is possible to drill and install some tiny roll pins to catch the tabs.
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Last edited by GoMotor; 02-12-2017 at 12:25 PM.
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