Doohickey, uh oh! - Page 2 - 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 #11 of 26 Old 03-06-2019, 06:12 PM
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I'd sure like to know...

I'd sure like to know...
what he LIKELY did wrong to F up this fairly straight-forward Project of 'The Doo'
as I'm about to FINALLY undertake mine (20,250m).
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post #12 of 26 Old 03-06-2019, 06:57 PM
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Putting the rotor on the crankshaft and cleanly engaging the woodruff can be tricky, especially if one puts the sprag clutch on first. It is much easier to install the clutch into the rotor and then install the whole mess.

The key is soft and serves only to position the rotor on the crankshaft so that ignition timing is correct. If the rotor is installed with the woodruff key not aligned to the crankshaft it is possible to torque the bolt down and crush and shear the key. When that happens the sprag clutch will be forcibly (as in 'holy ****ing shit! forcibly) cocked in the bore in the back of the rotor. This, of course, will bind up the sprag clutch and it will not spin freely. It will drag the starter motor along with it if the engine happens to start (which it might if the crank is only off a handful of degrees). At the very least horrible noises will emanate from the general direction fo the shop in which the bike is located, not the least of which come from the mechanic.

When the rotor goes on the crankshaft and engages the key properly, it goes on very cleanly. If it is not engaged it feels wobbly and rocky. The proper torque sequence on the bolt is to tighten it up to a few foot pounds and then back it off and do the full torque. Unless you are sure that the rotor has been properly assembled it is a good idea to spin the ring gear in a clockwise direction before backing the bolt off for final torque. If the key is not right, the sprag will bind and the ring gear will not turn in either direction.

One advantage to installing the sprag clutch first and then attempting to install the rotor to it and the key at the same time is that it is impossible to misalign the key and get the rotor onto the sprag clutch. Something to consider.

TLDR> He smushed the key and bound up the sprag clutch and who knows what else and it was all horrible and depressing. Dunno if it got fixed.

Tom [email protected]

“You talk too damn much and too damn much of it is about you.” -Philip Marlowe

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


Sting like a butterfly.

Last edited by Tom Schmitz; 03-06-2019 at 07:00 PM.
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post #13 of 26 Old 03-06-2019, 07:05 PM Thread Starter
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Thats cause it just went into my local dealer yesterday as they were backed up.....Still waiting to hear from them- Not very patiently mind you.
I was reminded a few times that I should not fix what is not broke, and they never see Doohickey issues- blah blah blah.......
I explained i am humble, lesson learned, asked for forgiveness, and am hoping they don't put the screws to me too terribly.... I really disliked having a 432 pound paper weight. I need to ride, even if its chilly.,

And Tom, that sounds like EXACTLY what i most likely did......

Last edited by mwt1974; 03-06-2019 at 07:07 PM.
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post #14 of 26 Old 03-06-2019, 07:24 PM
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I hope it all gets back together well and soon.

Too late now but, for future reference, a smushed key can seem to be virtually welded into the slot. Careful work with a Dremel and abrasive slotting disc will usually allow it to be pried out once a channel gets cut down the middle of it.
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Tom [email protected]

“You talk too damn much and too damn much of it is about you.” -Philip Marlowe

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


Sting like a butterfly.
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post #15 of 26 Old 03-06-2019, 07:35 PM Thread Starter
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Thanks Tom, Yea i tried everything i could think of to get that key out, short of dremel- or welding metal to the key as i really didn't want to make it any worse.

Hoping i didn't do anymore damage to the rest of the engine. Now the waiting game.....
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post #16 of 26 Old 03-06-2019, 08:56 PM
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Good luck man. I hope the beast is alright…

2017 KLR in black
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post #17 of 26 Old 03-15-2019, 10:02 PM
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wow i guess things can and do go wrong once in a while. im praying for ya buddy.


2009 KLR 650 Black and red, 12000 miles
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post #18 of 26 Old 04-09-2019, 04:30 PM Thread Starter
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2 Months!!! yes thats how long my dealer sat on the bike. But she is back on the road and all is well!

Yes, as expected, somehow misaligned the key while putting the rotor on.

Back on the road, and at the end of the day, i am grateful nothing else was damaged.
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post #19 of 26 Old 04-09-2019, 05:00 PM
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thanks for the follow up post

Dave
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post #20 of 26 Old 04-10-2019, 07:21 AM
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Quote:
Originally Posted by mwt1974 View Post
2 Months!!! yes thats how long my dealer sat on the bike. But she is back on the road and all is well!

Yes, as expected, somehow misaligned the key while putting the rotor on.

Back on the road, and at the end of the day, i am grateful nothing else was damaged.
Did you ask the dealer how they removed it? I am just curious as it is always good to learn new techniques for situations like this.
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