2008 recall... - Kawasaki KLR 650 Forum
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post #1 of 11 Old 02-28-2009, 06:27 PM Thread Starter
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2008 recall...

Just got a letter about the muffler bolts...yep I lost two, but replaced them and loctited them in. Apparently there is also an issue with the main harness.

Here is the Q - I called the dealer and he said to bring the bike in...I mentioned that there was some rubber rot...the shroud over the clutch cable on the side of the bike is rotted ("accordion" shroud). I asked if they could replace that and he kind of hemmed and hawed about whether warranty would cover it. He wasn't being a dick...I found a cool dealership, but I was just wondering what my rights are. Any help, thoughts, commiseration appreciated.

Oh, and it says in bold on the recall that I CANNOT ride my bike until I have the repairs done. But towing is not covered. I'm kind of pissed if you couldn't tell.

I never got a recall notice about the turn signal stalks...anything else I should know about?




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #2 of 11 Old 02-28-2009, 06:47 PM
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My thoughts: Do some interweb research and find out what the deal is with the harness and fix it yourself. As for the rubber rot, I've found it to be a fairly common thing on California bikes...just get a new part...it's gotta be cheap, not worth your back and forth time to the dealer.

Just because there is a recall doesn't mean that you HAVE to do something about it. I've got an outstanding recall item on my Buell, I'd fixed it myself already and don't feel like spending my time/energy to get it fixed thier way.

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Larryboy, you're brilliant!!


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post #3 of 11 Old 02-28-2009, 07:40 PM
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I've never gotten any recall notices on mine.

I believe that if you take the bike in for the exhaust bolt recall, all they are going to do is put the bolts in really tight. You can do that yourself, obviously, as you did.

Check the tightness of bolts periodically and you'll be OK. The thing, like all thumpers, vibrates a lot. Blue Loctite is your best friend (but I'm sure you already know that).

The rubber rot issue seems to have been fixed, at least on the turn signals, as an in-line change. Mine was built in November of 2007 and the signals have been fine. The clutch lever boot is rotted, as are the well nuts on the windscreen. Not critical.

The harness issue - look for a wire that goes over a bracket near the starter solenoid (under that plastic cover that secures with a big philips head screw) and slip a bit of rubber tube over it. Also look for areas that may have chafed under the tank and either wrap them with tap or put some tube around them. I haven't had an issue under the tank yet, but I keep looking for it. I did take some zip ties and secure the harness a bit better. That may have helped. Dunno for sure.

Next time you have the tank off, take those rubber pucks off and glue them on with your favorite wonder glue. That makes the tank re-installation easier and keeps them from falling off and rolling under the work bench. Ask me how I know...

They re-routed the carb vent, but it can still get blocked. After a couple of dirt naps, mine got some gas in the vent tube. After getting out of the desert and back on the highway, the gas which had collected in the tube all ran together and blocked the tube. I had to run home with a very sick feeling bike for almost 150 miles because I was too dense to figure it out. Do the T-Mod.

The PCV (Mercedes valve) mod is a good one, too. It may help with oil consumption.

The petcock vacuum diaphragm can poop out after time. Getting rid of the vacuum function on the petcock is not a bad idea.

In Thailand, where the bike is built, grease must be a precious commodity, because they don't put much more that 1/2 teaspoon in the whole dang bike. Pull the swing arm and the shock pivot and grease liberally as soon as possible. When you pull the swing arm, loosen up the rear engine mount bolt - this will allow the swingarm to be R&R much more easily. Don't forget to retighten that engine mount bolt. I did mine (I also installed zerks so that I can lube it easily) and the main swing arm bolt was starting to rust at 2000 miles. That's here in SoCal, where I've never been anywhere near any water...

Tom

Last edited by Tom Schmitz; 02-28-2009 at 07:48 PM.
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post #4 of 11 Old 03-01-2009, 07:18 PM
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I got the same recall notice yesterday in the mail for my 2009. Plan on having the dealer come pick up the bike... We'll see how well that works.


Blue '09 KLR650
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post #5 of 11 Old 03-03-2009, 12:33 PM
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Originally Posted by AzulMule View Post
I got the same recall notice yesterday in the mail for my 2009. Plan on having the dealer come pick up the bike... We'll see how well that works.

Updated report. I called the dealer this morning and they picked up the bike 30 minutes later. No charge! Good so far. Bad side, 7-10 days for the parts and repairs.

Blue '09 KLR650
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post #6 of 11 Old 03-03-2009, 12:48 PM Thread Starter
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Wow, can't believe they picked it up.

Tom and Larryboy, I hear you, but the bike needs a new tire, too, so I'm gonna let the dealership deal with this one. Probably give me something to work on.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #7 of 11 Old 03-03-2009, 10:39 PM
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I took mine in today to have it squared away.
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post #8 of 11 Old 03-04-2009, 10:57 PM
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Lockjaw, I thought you got all your bolt issues taken care of at the Tech Day.

When I got my notice, I call the dealer and asked them if would tighten them on my after market muffler. They said no so I did not bring it in.

Craig
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post #9 of 11 Old 03-05-2009, 09:54 AM Thread Starter
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Yeah, I did. LOL

I told them not to mess with the bolts as they are well and good loctited in. They're going to check the main harness and put a gripster on the back for me.

Oh, and I'm trying to get the crumbling POS clutch shroud replaced. We'll see.

Good memory man.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #10 of 11 Old 03-05-2009, 09:56 AM Thread Starter
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Ah, now I am guessing you refer to the infamous Mark B4 bolt issue. Ha! Sorry, subtle humor and I don't live in the same hood before 9 in the AM.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
Lockjaw is offline  
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