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From what I have read a lot (all ?) of the 2008 KLRs engine cases were machined with the starter shaft too deep. I wonder How many were caught and fixed early, how many just barely hung on without making noise and eating some aluminum off the case, and how many owners just kept using it that way. Simple fix, but just curious. Of course it it was an oil burner also, I suspect a lot of this yr model got resold several times. What’s your take on this ?
 

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Still Have My Second Canadian Spec 2008 KLR Red and silver. The first was an early 2008 model, made in late 2007. The first one was purchased in April 2008 but the early spec made one would not start when I went to Pick it up from the Dealership. it took 2 hrs to get it going I rode it home it felt more like a 250 or less no power it would not start the next Day, could not get an answer from the Dealership left numerous Message's, they did not contact me until late Tuesday as it was a Bank holiday Weekend, they took the Bike Back and prepared me a second Bike, I had taken the first bikes VIN down as a precaution!!. The second Motorcycle was made in February 2008 and had the usual issues, the Signal light recall. Exhaust bolt Recall and the wiring recall I have covered 19,000 km, from New. I have just checked my valve Clearance's and the L/H valves inlet and exhaust are just out of spec so I have ordered shims for that. I have Done the do hickey, done at 3000km whilst I am doing the Valves I have removed the L/H engine side cover, My bike has the deep hole problem, I have just finished making a 3/8 Long spacer from a 3/8 Diameter Stainless Steel Bolt to rectify the problem. There is no visible damage to the inner or outer cover casings or gears luckily. The Original Dealership is now gone, and a new Dealership has opened up although the owner has been around Bikes all his life His dad used to own Honda Dealership When I mentioned the Deep hole issue to the new Dealership he had no Knowledge of this issue and the only way to resolve it was to purchase a new outer cover I think it has a Revised Part Number. I am shortening the side stand also as the Motorcycle blew over recently whilst outside with a cover on it.Mine was run in carefully,has Never Burned Oil does not have the Thermo Bob Installed, and has the oil and filter changed at the end of each seasons use, I still use Kawasaki Mineral oil and Kawasaki Filters, I have thought of using Shell oil but with my Mileage does not seem worth it, This is not my only motorcycle. I have just retired from a life time of working in the automotive industry and the main thing I learned was to always use factory filters,and the best oil available of the correct specification for the temp where you live and do not flit from one brand of oil to another I always used to use Silkolene in my cars trucks and motorcycles when I lived in England, I used to live close to the Factory In Belper Derbyshire. The one engine problem I had on an old 1964 triumph Cub was from mixing oil brands I had run out my own oil and borrowed a friends oil (he used a Different Brand) to top up mine I had a partial seizure on a Trial competition several miles later on a fast part between sections, I did not finish.I sent the oil away to get it tested and was told that the Additves in my friends oil mixing with mine, most likely caused a problem leading to the Seizure.
 

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From what I have read a lot (all ?) of the 2008 KLRs engine cases were machined with the starter shaft too deep. I wonder How many were caught and fixed early, how many just barely hung on without making noise and eating some aluminum off the case, and how many owners just kept using it that way. Simple fix, but just curious. Of course it it was an oil burner also, I suspect a lot of this yr model got resold several times. What’s your take on this ?
I'm surprised that I had not seen this posting until just now. Because I do occasionally check 'New Posts' 2 weeks back.

But I really don't have much info to share.

When I do a Doo-Hickey, I usually hang the outer cover with stator wires still connected to the main harness from a piece of mechanics wire past around the forward LH sidepanel screw & resting on the LH riders footrest.

I then remove the starter reduction gears, thrust washers and the single shaft and insert them into their respective holes in the outer cover. If I hadn't noticed a Deep Hole behind the steel bushing during cover storage, I would certainly find it now. the single bearing shaft would not protrude thru the needle bearings, so no place for the 4th thrust washer.

I know that there are both early & later 2008 & 2009 models that we sold that were never even returned for the factory recalls.

ps, April 13, 2018, It appears that this was my 5000th posting in this forum & I've been shifted into that ever so elusive 'overdriven' 6th gear.
 

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From the original discussion started in 2009;

VINS 00001 through 20749 all have the deep hole (that's all '08s, some '09s).

VINS 20750 to 20802... might or might not... we're looking for data in this range.

VINS 20803 and above: do NOT have the deep hole.

Hope this helps.
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