1990 KLR Tengai Resto-mod.... Maybe - Page 6 - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

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post #51 of 108 Old 01-06-2020, 01:24 PM
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Keen to see the differences across these.

EagleMike does sell a shim set to allow the user to add tension to the assembly and reduce the tendency of the sprocket to walk back-forth on the output shaft (that slop increases the wear on the shaft -and big-K don't make these anymore).

I had taken to inserting washers between the keeper place and the sprocket: the sprocket was then forced inward up against the collar on the shaft, and the keeper plate was then forced outward against the splines on the shaft.

This technique appeared to work well on my original '95 Barbie Bike and there was very little play between the sprocket and shaft when I sold it with 45k miles on it (thanks to the great recession :-( ).

Using the same approach on my Orange '87 playbike with the '89 motor and it has worked well there too. Now at about 40k miles, and has the 685 kit, KLX, opened airbox, ex cam on tooth advanced, 09 head pipe and Lexx exhaust.

More than one way to skin a cat, so I'm always interested in the considered opinions of others.

Last edited by foo; 01-06-2020 at 01:37 PM.
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post #52 of 108 Old 01-06-2020, 03:04 PM
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It was @GreatWhiteNorth that set me straight here. What I had around the shop was the 13270 and the 13169 part. They looked identical to the parts that GWN showed in his picture. Both of my parts have the same bolt spacing at 42mm and I assumed that all KLR plates and sprockets were the same until KHI went to a nutted output shaft. I never had a need to mate the plate with a new sprocket.

If GWN had not pointed out that the 13183 part had a 38mm bolt spacing I’d still be thinking wrong. I don’t like thinking wrong.

Today was a good day because I learned something.

Here’s a thought I had that I shared with GWN:

“You know what's funny and ironic and shows that the world doesn't work right?

Companies like JT thread the sprockets with 38mm spacing because that is what the KHI spec was for the later sprockets. Yet, that plate is not available, so those sprockets are useless if your plate is worn out. They should be threading them with 42mm spacing, then everybody from '84 to '96 would be happy.”

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

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

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post #53 of 108 Old 01-06-2020, 05:25 PM
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Quote:
Originally Posted by pdwestman View Post
The higher strength steel retainer plates from Eagle Mike have 'slots' instead of bolt holes to allow fitment onto either of early or middle Gen 1 transmission shafts.

(And an assortment of spacers & shims to center the various brands of sprockets & take up as much lateral movement as possible is SOLD SEPARATELY.)
I wish Eagle Mike's site had a picture. It is actually ITEM #1 on this page, https://www.eaglemike.com/KLR650-200...earlier_c2.htm


And the sprocket shim kit is a ways away, to the RH side of Sunstar & prevailing torque nut, about midway down on second page and again is lacking of a picture,
https://www.eaglemike.com/KLR650-200..._c2.htm?page=2

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Modify at "YOUR OWN RISK"!

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Last edited by pdwestman; 01-06-2020 at 05:29 PM.
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post #54 of 108 Old 01-06-2020, 05:40 PM Thread Starter
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Well Dang... COME ON KAWASAKI! THanks for making this so easy on me. Jerks. HAHA

SO, What one will I need to fit my 1990 Tengai?

Also, ALL the way from London... I got a present to myself in the mail!
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post #55 of 108 Old 01-06-2020, 06:51 PM
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You could just upgrade to a '96+ engine, and not have to deal with that problem. The '96 and newer use a thread on nut to secure the front sprocket, have an extra clutch friction disk in the clutch pack, solid balancer weights (not failure prone like pre '96)in the counterbalancer system... lots to like there. I can appreciate, from a nostalgia perspective, folks wanting to keep the oldies in service, but (because of the oil burning issue) '08 & '09 engines come up for sale with toasted heads once in a while. Good upgrade if you can get one cheap. I've gotten three '08 bottom ends like that, pooched heads, resuscitated 'em with an aftermarket piston and refreshed head.
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post #56 of 108 Old 01-06-2020, 07:08 PM Thread Starter
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Originally Posted by GreatWhiteNorth View Post
You could just upgrade to a '96+ engine, and not have to deal with that problem. The '96 and newer use a thread on nut to secure the front sprocket, have an extra clutch friction disk in the clutch pack, solid balancer weights (not failure prone like pre '96)in the counterbalancer system... lots to like there. I can appreciate, from a nostalgia perspective, folks wanting to keep the oldies in service, but (because of the oil burning issue) '08 & '09 engines come up for sale with toasted heads once in a while. Good upgrade if you can get one cheap. I've gotten three '08 bottom ends like that, pooched heads, resuscitated 'em with an aftermarket piston and refreshed head.
You obviously haven't read this thread at all..
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post #57 of 108 Old 01-06-2020, 07:23 PM
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Quote:
Originally Posted by ironranger88 View Post
Well Dang... COME ON KAWASAKI! THanks for making this so easy on me. Jerks. HAHA

SO, What one will I need to fit my 1990 Tengai?

Also, ALL the way from London... I got a present to myself in the mail!
Ohhh - Tengai plastics ?!?!? If those are in good shape -You are a lucky man!

And FYI, the Sunstar 33316 I got from Mike last week measures 42mm from center to center. Fine print on the package lists several bikes as compatible, including KLR600/KLR650 '84-'89.

Mike only sells a single retailer plate, so I'll find out if the plate and sprocket work on the '95.

However - in lining up the retainer against the sprocket, it appears that the retainer has big enough openings for either the 38mm or 42mm sprockets. So at this point I think I'm good to go for either my early Gen 1 or the '95 Barbie.

Last edited by foo; 01-06-2020 at 07:58 PM.
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post #58 of 108 Old 01-06-2020, 07:37 PM
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You obviously haven't read this thread at all..
Actually, I have. Each to their own, but IMO not worth trying to upgrade a pre '96 engine. I genuinely paid around $300 Cdn, approx $210 USD each, for used '08 engines, ran low on oil ruining the heads, that were easily resuscitated. For a while those (pre '96) front sprocket retaining spline plates were unavailable from Kawi... according to the E-M website still are. I put a '96+ engine in my '94, never looked back.
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post #59 of 108 Old 01-06-2020, 08:08 PM
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He's got the original(ish) bottom end with a good transmission but a bad head and has an '08 bottom end with a pooched transmission but a good head. His hope is to put the old transmission into the '08 case, though his original plan was to use the '08 engine complete before he discovered it had a pooched tranny.
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Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem
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post #60 of 108 Old 01-06-2020, 08:11 PM
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Quote:
Originally Posted by foo View Post
...

Mike only sells a single retailer plate, so I'll find out if the plate and sprocket work on the '95.

However - in lining up the retainer against the sprocket, it appears that the retainer has big enough openings for either the 38mm or 42mm sprockets. So at this point I think I'm good to go for either my early Gen 1 or the '95 Barbie.
@pdwestman confirmed that, above. I'd like to see a picture of the part, though. I wonder if he has found some odd slotted plate or is milling the hole into a slot on one of the available OEM plates.

If I could get into the attic of my shop I'd drag out some Sunstars to have a look-see. The JT I have on my bench are 38mm.

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem
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