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Discussion Starter #1
I searched the forum and did not find anything. Is there a good place on the KLR to install an oil temperature sensor? I am looking at a Trail Tech Voyager and see it has an input for a temp sensor and an adapter to use that sensor for oil temp measurement. That adapter has M18x1.5 threads. Is there a port on the KLR that will accept this adapter?

If not, any other location that would be a good place to sense oil temp?
 

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I use a Trail Tech V300-001 sensor that I have installed at the test port. The test port is on the clutch cover way down near the water pump. It is directly below the oil filter at the bottom of the case. It is necessary to drill and tap the test port screw to M6, but this seems to me to be a good spot for oil temperature.

See this:https://www.klrforum.com/657330-post23.html

You would not have found it unless you searched for "oil temperature test port" and you wouldn't have known to search for that unless you had written the post and knew the keywords to use ;^). Forum search engines generally suck.

This may also help; the test port is where I stick the pencil in at 0:45:
 

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Discussion Starter #3
I use a Trail Tech V300-001 sensor that I have installed at the test port. The test port is on the clutch cover way down near the water pump. It is directly below the oil filter at the bottom of the case. It is necessary to drill and tap the test port screw to M6, but this seems to me to be a good spot for oil temperature.

See this:https://www.klrforum.com/657330-post23.html

You would not have found it unless you searched for "oil temperature test port" and you wouldn't have known to search for that unless you had written the post and knew the keywords to use ;^). Forum search engines generally suck.

This may also help; the test port is where I stick the pencil in at 0:45:
https://www.youtube.com/watch?v=l927rWUCQQ0&t=0s&index=9&list=PL3s67DOJbACxpudHWt11Lnxsk6qfUuwYT
Thanks! As luck would have it, no, I did not use that exact string. :grin2:

Do you have an aftermarket skid plate that protects the sensor? Or is it not that vulnerable?
 

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It is pretty well protected by almost any skidplate. Mine is a Richochet which it the most ubiquitous skidplate on the market for a KLR.

"Ubiquitous skidplate" is not something I ever anticipated saying...

 

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Discussion Starter #5
I use a Trail Tech V300-001 sensor that I have installed at the test port. The test port is on the clutch cover way down near the water pump. It is directly below the oil filter at the bottom of the case. It is necessary to drill and tap the test port screw to M6, but this seems to me to be a good spot for oil temperature.

See this:https://www.klrforum.com/657330-post23.html

You would not have found it unless you searched for "oil temperature test port" and you wouldn't have known to search for that unless you had written the post and knew the keywords to use ;^). Forum search engines generally suck.

This may also help; the test port is where I stick the pencil in at 0:45:
https://www.youtube.com/watch?v=l927rWUCQQ0&t=0s&index=9&list=PL3s67DOJbACxpudHWt11Lnxsk6qfUuwYT
I think I found the Kawasaki part number for the plug you drilled out (92066-1156), but the description does not give the size or thread pitch. Do you recall what it is? My plan was to buy the Trail Tech adapter if they have on of the correct size. They have a range of sizes. I don’t have the machining capability you have and I am not sure I can drill the plug by hand square enough to have things seal up.
 

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I'll have to go into the Shed of Horrors and go through some bits to find one and measure the threads. Might take until tomorrow.
 

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Discussion Starter #7
It is pretty well protected by almost any skidplate. Mine is a Richochet which it the most ubiquitous skidplate on the market for a KLR.

"Ubiquitous skidplate" is not something I ever anticipated saying...

I didn’t know there was a ubiquitous skid plate. I had not yet come across the Richochet product. I have looked at Happy Trails, SW-Motech, JNS Engineering, and I think one or two others, but somehow missed Richochet. Is there a master list of “ubiquitous” parts and accessories so I don’t miss anything else? :grin2:
 

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Found one! It is M10X1.25.
 

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Ricochet was kinda sorta the original and made them for others, including HT if I am not mistaken. Pretty sure I bought mine through HT. They sold them under their own name as well.

Then everybody and their dawg who had a waterjet machine started making KLR skidplates. HT has moved on from Richochet and I don't know who makes theirs now.
 
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There is enough meat on that case to tap it out to M12. Pretty sure about that. I might try that tomorrow.

I'll have to look at the TT adapter. It would be good to get the body of the sensor just a bit into the oil flow.

edit: Looks just like the OEM fitting, so should work the same re getting the tip of the sensor into the oil flow.
 

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Discussion Starter #13
There is enough meat on that case to tap it out to M12. Pretty sure about that. I might try that tomorrow.

I'll have to look at the TT adapter. It would be good to get the body of the sensor just a bit into the oil flow.

edit: Looks just like the OEM fitting, so should work the same re getting the tip of the sensor into the oil flow.
I was looking at these. I figured if they made one that fit the stock hole, for $10 it would be worth just buying one. However, since they don’t make one small enough, might as well drill and tap a stock drain plug rather than drill and tap the case.
 

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Working on the plug is easier than the case but you have to center the new hole pretty much dead nuts. Perfectly centered you have but .046" of metal between the exterior and interior threads. Take .010" away from that for true positioning errors and it's sketchy. Fortunately, the screw needs no torque and holds nothing but itself in place. And, if it does break, the sensor will hold things together and prevent a dramatic leak. This is a feature I refer to as 'graceful degradation of the spawn of the Shop of Horrors'... Of course, if you screw it up you're only out $5, so the smart game is to drill and tap the expendable plug.

As it turns out I am not a smart man (and I won't get to it until tomorrow) but I will let you know about tapping a clutch cover. The challenge there is keeping the re-tapped hole square to the spot face since the case is such a bugger to set up. I'm going to free-hand it and see how it goes.
 

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Ricochet was kinda sorta the original and made them for others, including HT if I am not mistaken. Pretty sure I bought mine through HT. They sold them under their own name as well.

Then everybody and their dawg who had a waterjet machine started making KLR skidplates. HT has moved on from Richochet and I don't know who makes theirs now.
Yep the Ricochet was sold under several banners......sorta like Dynojet jet kits.

Dave
 

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Discussion Starter #16
Working on the plug is easier than the case but you have to center the new hole pretty much dead nuts. Perfectly centered you have but .046" of metal between the exterior and interior threads. Take .010" away from that for true positioning errors and it's sketchy. Fortunately, the screw needs no torque and holds nothing but itself in place. And, if it does break, the sensor will hold things together and prevent a dramatic leak. This is a feature I refer to as 'graceful degradation of the spawn of the Shop of Horrors'... Of course, if you screw it up you're only out $5, so the smart game is to drill and tap the expendable plug.

As it turns out I am not a smart man (and I won't get to it until tomorrow) but I will let you know about tapping a clutch cover. The challenge there is keeping the re-tapped hole square to the spot face since the case is such a bugger to set up. I'm going to free-hand it and see how it goes.
Probably the really smart game is to buy a new plug from Kawasaki and drop it off at a competent machine shop and have them drill and tap it for me. :grin2:

I am sure that will cost more than the pretty red anodized adapters from TrailTech, but since they don’t offer them in the right size...
 

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That would be the smart play. It's not that hard if you have a magnetic v-block to set the plug in so that you can accurately scribe the center point to drill. Then mount a piece of scrap bar in a vise, drill, tap, and spot face it, screw the plug in and drill and tap it. The real work is in making the mounting piece! If you're not in a big hurry I'd be glad to make you up one and send it to you. Them damn pirate machinists will charge you shop rate unless you can find one that works for beer.

Since I have covers to play with and am likely to have my cover off at some point in the future (a symptom of not being able to leave well enough alone) I figured I'd give it a whirl. In case the process became horrible and depressing I risked a cover that probably won't see any future use.

There is plenty of material to work with.


Drilling it out was done in three steps to minimize the potential for the drill to wander off-axis.


The pilot hole came out nice and square to the port face. It had to be done free-hand because I don't have an angle plate anywhere near big enough to support the case and, even if I did, the passageway is at a compound angle to the gasket surface and I'd never get it right without a vertical sine plate. Those run about $2000. Funny story; Good Neighbor Ray was milling some Delrin last week to make a switch handle and was having some trouble figuring out how to mill a not-terribly-critical 25° angle on both sides of the paddle. I told him he ought to make a sine plate to mount his vise on. Out of plywood and a door hinge. He did and it worked like a champ. Necessity is a mother...

I've gotten overcome by events and will tap it tomorrow. The Trail Tech adapter will probably be here early next week.
 

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That would be the smart play. It's not that hard if you have a magnetic v-block to set the plug in so that you can accurately scribe the center point to drill. Then mount a piece of scrap bar in a vise, drill, tap, and spot face it, screw the plug in and drill and tap it. The real work is in making the mounting piece! If you're not in a big hurry I'd be glad to make you up one and send it to you. Them damn pirate machinists will charge you shop rate unless you can find one that works for beer.

Since I have covers to play with and am likely to have my cover off at some point in the future (a symptom of not being able to leave well enough alone) I figured I'd give it a whirl. In case the process became horrible and depressing I risked a cover that probably won't see any future use.

There is plenty of material to work with.


Drilling it out was done in three steps to minimize the potential for the drill to wander off-axis.


The pilot hole came out nice and square to the port face. It had to be done free-hand because I don't have an angle plate anywhere near big enough to support the case and, even if I did, the passageway is at a compound angle to the gasket surface and I'd never get it right without a vertical sine plate. Those run about $2000. Funny story; Good Neighbor Ray was milling some Delrin last week to make a switch handle and was having some trouble figuring out how to mill a not-terribly-critical 25° angle on both sides of the paddle. I told him he ought to make a sine plate to mount his vise on. Out of plywood and a door hinge. He did and it worked like a champ. Necessity is a mother...

I've gotten overcome by events and will tap it tomorrow. The Trail Tech adapter will probably be here early next week.
That would be a very nice solution if the case drill and tap works well. I was about to ask if you had spare case covers as you seemed so willing to start drilling on one.

I am in the process of commissions a new workshop, but haven’t got my equipment moved into it yet. I just got the boiler working a month ago and was hoping to get the floor painted before moving my drill press in. However, that isn’t going to happen until spring. I might just move my drill press into the shop as that should make drilling the case a less daunting proposition. I could run a tap into the existing hole, chuck that in the drill press to establish alignment, and then try to find a way to secure the case in that position. It then should be fairly straightforward to drill out the hole squarely and tap it to the new size. I wonder if the case will need to be spot faced larger to accept the Trail Tech adapter?

Do you have a source for reasonably priced case covers? I would be more inclined to drill mine if I had a fall back should the excrement hit the ventilator.
 

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Cases are usually cheap on e-bay. You can use anything from '96 on up. You could even use an earlier one but you'd have to use the older style clutch rod and there is no good reason to do that.

Here's a '97 for $38, but he'll take offers. But wait! It even comes with the test port plug, a $5 value absolutely free. It also affords the opportunity to install a kickstarter if you happen to be fond of slippery slopes.

I have a Gen 2 case, an '09, I think, that you could have for the cost of shipping. We'd have to get an estimate on what that would be going UPS ground. This was the case in the video above, so it has the 100% filtration mod done to it.

Neither one of these will match the color of your engine, so a bit of paint would set that right. There's a black '12 on ebay for $60 if that seems reasonable to you.
 

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Cases are usually cheap on e-bay. You can use anything from '96 on up. You could even use an earlier one but you'd have to use the older style clutch rod and there is no good reason to do that.

Here's a '97 for $38, but he'll take offers. But wait! It even comes with the test port plug, a $5 value absolutely free. It also affords the opportunity to install a kickstarter if you happen to be fond of slippery slopes.

I have a Gen 2 case, an '09, I think, that you could have for the cost of shipping. We'd have to get an estimate on what that would be going UPS ground. This was the case in the video above, so it has the 100% filtration mod done to it.

Neither one of these will match the color of your engine, so a bit of paint would set that right. There's a black '12 on ebay for $60 if that seems reasonable to you.
Given the ready availability, I likely will modify my own cover first and then it will be “period correct color” assuming success. If not, then the $60 one will start looking pretty reasonable!

I did notice that apparently only the -003 oil temp sensor works with the adapters. Surprising they don’t have adapters for the -001 as its skinnier size would seem to open up a wider range of potential locations, such as the KLR test port.
 
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