Another in the stable, but that?..... - Page 4 - Kawasaki KLR 650 Forum
Other Bikes Theres room for everyone, even if you don't have a KLR.

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post #31 of 38 Old 02-05-2019, 10:30 PM Thread Starter
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Quote:
Originally Posted by terry_g View Post
If I'm not mistaken there is a special grease that goes on the clutch spline and hub.
My 85 K bike owners manual says to pull the transmission and lube the splines every 15000km.
They changed the material in the 1989 K bikes and extended the interval to 45000km.
I use Parker Hydraulics spline lube on mine it has amazing staying power.
I will see if I can find a part number for it.

Terry
My buddy dropped off two tubes of different grease for the project. He currently has two Beemers, and keeps up on the maintenance stuff himself. He even loaned me the special toothbrush applicator for the stuff.

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

Jeff in Napa California

Last edited by campfire; 02-23-2019 at 09:03 PM.
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post #32 of 38 Old 02-12-2019, 10:05 PM Thread Starter
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UPDATE!

Just got an email that the part is in from Germany and will/is being shipped today.

Sidenote-----------------
Took the KLR out for a ride the other day for a 148 mile loop up in the hills around here. It's been unusually cold around here, and there was snow everywhere. Rode with my buddy that was on his 1200RT with heated grips, fairing galore, etc. I was again very content on my "simple" thumper.
After working on this thing more and more, and hearing stories about all the do's & don't's, I'm finding myself very content with the KLR.
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Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #33 of 38 Old 02-16-2019, 11:45 PM Thread Starter
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I've been working all week on this thing off & on, and spent almost all of today on it.
The transmission went well with the new shaft installed, but had an issue with the clutch hydraulics not feeling right. So I flushed the system with DOT 4 and tried bleeding the system, only to clean the cap and see "Mineral Oil Only".
More cleaning and flushing (i don't think DOT 4 being in there for 15 minutes is going to ruin anything), three trips to search for V10 or Magura blood got me some Motorex 75 at the Harley place.
Clutch lever works great now and feels better.

Should have it running tomorrow or Monday. I'll post up a final and pictures.

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

Jeff in Napa California
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post #34 of 38 Old 02-18-2019, 10:38 PM Thread Starter
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Well.......
The integrated ABS is a serious pain to bleed. Had to disconnect the rear lines to split the bike. Haynes manual is very vague, and then the factory manual on DVD is missing a couple of steps I think.
It’s back in pieces trying to get the brakes done.


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

Jeff in Napa California
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post #35 of 38 Old 02-20-2019, 10:35 PM Thread Starter
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Finished it up last night and took it out for a little spin (8 miles).
Then I worked on a couple of details, checked the brakes one more time, even went out to DMV and took the Non-Op off of it and paid the registration for new tags. Signed up for insurance so I'm all legal, and then rode it for 23 miles today.
It seemed a little rough and had some serious popping on decel, so I checked the cylinder balance and sure enough, it was way off. Dialed that in and it runs a lot better.




Going to take it out tomorrow toward the coast I think, if the weather works with me.



While I have found some really nice features on this bike, I took the KLR for the DMV run and loved it.
If you want to make a KLR feel light, ride a GS for a few miles then get back on the KLR.

Maybe I'll post some coast pictures tomorrow.
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Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #36 of 38 Old 02-21-2019, 03:08 AM
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I know it was a lot of work, but you've got a really nice bike as a result. Congrats!

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -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 #37 of 38 Old 02-23-2019, 10:04 PM Thread Starter
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So I took off for the coast from Napa and was so happy that the project was mostly complete except for some small details and finish work. On the way over to Petaluma 38 miles away, I noticed that the shift indicator was flickering between 6 and 4. That kept up for a while just bouncing around the gears even though I wasn't shifting.
I just figured it was just the sensor, and I knew what gear I needed to be in anyway. Thought I should top off with gas before heading out the back roads, so I stopped in Petaluma.
Fill up and .......... it won't start. I push it out of the way, try a few things, and then realize that the ECU (computer) must see neutral before it will start. Break out the tool kit, and try jumping across the starter terminals, no good. Cranks, but won't fire off.
Hit up Google on the phone, find the same issue in a thread on ADV. Terminals get dirty or loose, so I clean and reseat the connector. No start.
Guy posted that they could push start his. I try that, on flat ground, multiple times, it's not working.

Then it hits me, the computer must need to see a wheel sensor to push start it.

I put it up on the center stand, put it in gear, and jump the starter.
We have fire! It runs!

Screw it! I'm on the road for the coast and some clam chowder.

I make it to Bodega Bay and notice that half way there, the indicator started working.

I get my chowder lunch at Spud Point Crab Co.
The best chowder around, and heavy on the garlic.


And the view is pretty good too.


So with a full stomach, and a bike that starts, I'm a happy camper again.

Off for more riding. I head up to Bodega Head and it's a windy day for the Pacific Coast.



Must go North.






Turned out to a very good day with the new to me bike, but I'm not sure if I'm a big GS fan. Never really like longitude crankshaft motors with the torque twist in corners. Takes a lot of getting used to.
But it rides nice, plenty of power, and gets about the same mileage as the KLR.



Turned out to be a 148 mile loop ride for the maiden voyage, and a lot of fun.
Thanks for following along.
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Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #38 of 38 Old 02-24-2019, 05:15 AM
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Good deal! I'm impressed with your skills and the outcome, campfire!
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