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Discussion Starter #1 (Edited)
So my speedo quit on a ride. When I got home I started the investigation and this is what I found:



Bits of the hub jammed up the speedo gears:



This looks like a job for...



A piece of 1.5" pvc was a perfect fit for the outside diameter and a cap off a spray can worked for the inside. I used parafin wax as a release agent.



Here's the finished repair. This is after 200 miles or so, looks good no cracks:



Looking for a replacement hub I was surprised to find that this is not an unknown failure. I was talking to WymanWinn on the .net site and he recommended putting some grease in the slots and installing the drive gear. Then put the housing over it and install the wheel like that.

 

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Discussion Starter #3 (Edited)
Repair looks good! What do you think caused the failure originally? Did something bind up or lock up to cause the breakage?

Well the grease looked a little old and solidified. I vaguely remember cleaning and greasing it about a year ago! The cable was fine, turned easily.

I did find the slotted tab bent last summer sometime. What happens is that if the tab is not lined up in the slots it will get bent when the axle is tightened up. The speedo may or may not work. I just flattened it out and thought that was the end of it. Maybe it cracked the hub and it took this long to finally let go? Don't know.

That's why the advice to install the drive gear (with the tab in the slots) on the hub first, then the housing and then install the wheel. The cable has to be off of course until the wheel is back on.

I'm still looking for a hub, hoping the repair lasts until I can find one.
 

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Spec,
Thanks for the heads up on this. Very nice work with the J-B Weld.

I can hear, on my bike, what I thought was my cable making noise. Lubed it up and and no change in the noise. I'm going to pull my wheel today and lube up the drive gear. :)
 

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Turns out my drive gear and original grease all looked good. The gear had flung off most of the grease though. Cleaned the gears and greased them up. No change in my noise. I guess it's one of those KLR noises I will learn to love.
 

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I am aware years have passed from the last post was made on this thread... but could anyone (if not Spec himself?) provide the dimensions (hopefully in millimeters) of the actual repaired part?

- How tall should the hub be?
- What's the width from outer diameter to inner diameter(in other words how thick it is?)
- What's the width and hight of the 2 notches where the speedo gear hub will hook up?
- Does it matter that the metal part has some sort of inner lip at the top inner diameter making the section view look like a "P" while making a replacement this way it will have no lip?

Thanks in advance to anyone who will be able to provide an answer... mine is broken too so I can't take any measurements

Cheers + safe riding! :)
 

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Someone....can't remember who? Wattman maybe?

Anyhow someone posted pics of a fix that consisted of drilling a hole and inserting a spring pin to provide push on the speedo drive gear. Works fine without the hassle of trying to rebuild the flange.

Dave
 

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Very interesting thread. I just changed out by tires and the front brakes. While I was in there I repacked the bearings on the front and rear wheels. I did notice that there was a chunk of dried up lube, (talk about crusties), on the speedometer linkage hub. That is what prompted me to grease them up.
An ounce of prevention...
 

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@DPelletier That was great to see, it might just work and it's definitely one of those things that should be on the Kawasaki engineering team's list of improvements for future KLR models (one of several)! The image on that post helped although could not see it larger (as I got a "you do not have permission to view this page or perform this action" message when clicking on it... even if I was logged in) the thumbnail is large enough to see how the pins were positioned.

Thanks again to everyone and safe riding to all!! :)
 
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