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Discussion Starter #1
Has anybody had to replace the electric starter, Torque Limiter Clutch gear on a '08-up KLR 650? Part # 39076-1056, Limiter, Starter Idle Gear.
That is the Top gear in the electric start gear system.
 

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I haven't heard of anyone having to replace one yet... The 08's and early 09's were the ones affected by the deep hole problem, could that be related to the noise? (Haven't fixed mine yet even though I have the part from Eagle Mike, same with doohickey, lol!)
 

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Discussion Starter #3 (Edited)
This bike (Cody, WY), is one of the two '09s which I Schnitz 685'ved, back in the Winter of 2010. The two owners, friends/riding partners of mine, have been in-contact with each other. The other owner is living on Morro Bay, CA.
He says his '09, does Now, occasionally 'Squawk'! 1st cold start attempt of the day. Both bikes!
Bike in question, just rode Baja, Mexico. That is where the noise developed.

I've heard it, ONCE. In many attempts. Part is 'back-ordered'. Part has been super-ceded. That tells me something.

ps, both '09s were 'deep-hole' checked or corrected back in 2010.
pss, both bikes have EM torsion spring and Doo.
 

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Discussion Starter #4 (Edited)
Any of you guys that have removed the KACR, ever have any problem with the Back-Torque Limiter, 39076-1056?
Does anyone know their Max. Cold Cranking Compression, with KACR dis-abled or removed? 651cc vs 685cc.
 

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Someone recently reported getting 140 psi and thought it was strange until he remembered the compression release was disabled. I don't recall who, when, what gen or displacement.
 

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Discussion Starter #6 (Edited)
This is the '09 from Cody, WY. 13,700 miles.
Last spring Before I re-adjusted valve tappets this engine was pushing over 130 PSI. After valve adjust and MC mod, it pushed over 150 PSI, at 5347 ft of altitude.
Any mathematicians able to calculate Sea Level cold cranking compression from this info?

Full disclosure,
When it is was a stone stock oil burner/hard starter. It had less than 70 psi.
Re-cut (narrowed) valve seats and lapped valves along with the Schnitz 685 piston kit back in 2010. Also trimmed some height off the KACR pin at that time.
IT is Not the height of lift that is important with the KACR, It IS the Closing Point. Less Height closes Earlier. We had about 118 lbs, Freshly assembled, Not test started, COLD, in 2010.

So this engine has 4 things which has improved the CCC.
Good valve sealing, KACR mod, 685 piston kit, MC mod (exhaust cam advancement).

I'm thinking 150psi+ and sea level, the Limiter may have said 'too much'!

Maybe this might be part of the reason the Up-dated Limiter gear is on back-order? Lots of properly rebuilt 685, 688, 692, 705 KLR's out there.
 

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Discussion Starter #7
I believe Wyman Winn did the MC mod last year, on the other '09 ex-oil burner which is currently living in Morro Bay, CA. when he adjusted valves on that bike for my buddy Greg J.
I had done the exact same work on his engine back in 2010.

Question for Go Motor,
Do you have any idea if Wyman usually does a before and after CCC, with tappet adjustments?
 

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...........Question for Go Motor,
Do you have any idea if Wyman usually does a before and after CCC, with tappet adjustments?
I don't know what measurements Wyman does.

I do think that since on average there is about 22% more atmospheric air pressure at sea level than at 5,300 feet, the same engine would produce about 22% more psi of compression at sea level compared to 5,300 feet.
 

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Discussion Starter #9
+22%, Ouch. Potentially up to 183 psi at sea-level. That just might cause this issue.
 
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