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Discussion Starter #1
Left for Tellico Friday morning with a buddy and his XR650 and we made it to Crawfords Campground by 1030 am for a weekend of great riding and camping.

We unloaded the bikes and took off for the trail head. Deposited our funds in the drop box and continued up trail #1 to trail #4. About fifteen minutes into trail #4 and I bottomed out on some slickrock with a loud bang. I stop to look down and check things out and notice oil dripping at a rapid rate from base of the case.

Upon closer inspection, I see a large crack near my oil drain plug and the great life I was having just a couple of minutes prior on a brisk November morning in the NC mountains comes to screaching halt.

I looked at the rock and the mark left by my drain plug and it wasn't even a total shearing of the oil drain plug but more of a forward moving glancing blow off a rounded, smooth rock.

As I sit there watching the 15W40 drip from my engine (BTW...only had about 40 miles on fresh oil & filter), I'm cussing myself for delaying the purchase and installation of a skid plate and low profile magnetic drain plug!
What to do now??? My buddy finally comes back after about 10 minutes and we come up with a recovery plan:

I push my bike up and ride the downhill portions of Trail 4 back to Trail 1, which is basically a rough gravel road, and was able to ride it downhill a ways too. From there I take the XR650 back 11 miles to Crawfords to first clear my truck bed of firewood and second, to unhook from my trailer. 85 minutes later I arrive back to my buddy and my KLR and we load her up and head back to camp.

I proceed to drink beer and sulk the rest of the day Friday and we hit the hay around 10pm. Back home by noon Saturday. What a bummer. Now I have to figure out how I'm gonna fix my baby with only 2000 miles on the clock!

If anyone here has contemplated or put off getting a skid plate for their KLR, let my misfortune be a lesson for you. DO IT NOW, don't wait another day. Instead of investing about $100 for the above, now I'm gonna have to spend a lot of $$$$ to get my baby right again.

One positive thing I see from this is I won't be putting off checking valve clearance or replacing the doohicky now.

Enjoy the few pics I got to take......

Loaded up and ready to roll...


Another of before we leave...


Arrival at Crawfords Campground...


Bikes @ Campground office...


At the trail head fee station...


First scenic view...


Doesen't look good...


OMFG..what did I just do to my baby!!!


Back at camp with one broke KLR...
 

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Sorry to hear things got all crappy on ya at the beginning.
I've been putting the skid plate off for a while but I guess I better get to it soon.

I always thought of Tellico as a 4 wheeled destination. Are there a lot of Motorcycle trails down there?

Brian
 

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Discussion Starter #3
Sorry to hear things got all crappy on ya at the beginning. I've been putting the skid plate off for a while but I guess I better get to it soon.I always thought of Tellico as a 4 wheeled destination. Are there a lot of Motorcycle trails down there?
Brian
Thanks for your condolences...Get that skid plate ASAP!

Yes, most of Tellico is of the 4WD variety...but I feel almost every trail is a motorcycle trail.
 

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Same thing happened to my Dads KLR WITH a moose skid plate on. He took it to a welding shop and had it fixed. That was 2 years ago and it still is not leaking.
This spring, my son was riding my VStrom (with only 1200 miles on it) in Spokane when a car pulled out in front of him. He veered off to the right and went over a curb. Well, when he hit the curb, it pushed one of the brackets that hold the skid plate on, which has since been redesigned, thru the crank case. I roughed up the surface around the hole and patched it with JB weld. The putty type. I have put 8000 miles on it so far with no leaks.
Good luck with yours......
 

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Discussion Starter #7
As of now, it looks like insurance is going to cover this one.

It is the left center case that is cracked. Thats the only visible damage right now...could be more hiding.

Engine will be removed, disassembled, two new inner case halves installed, new aftermarket doohicky installed, valves checked/adjusted, and everything reinstalled.

Dealer said it "might" be done by end of next week. I said take your time and don't rush the job, insurance is covering it.

BTW...where is the best place to get a beefier doohicky (I'm supplying it at my expense)??? I'll need to get one quickly and bring it to the dealer so as not to hold them up.
 

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Go to arrowheadmotorsports.com for the doohickey. Or call them at: Phone: 435-259-7356 I would also suggest getting the new Torsion Spring they developed for the doohickey too. This should never have a fail issue with its new design.
 

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Well, kinda wondering how things turned out on this.

 

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Discussion Starter #10
Well, as of today, the dealer still has it. I forget the day I brought it to them but they've had it over 3 weeks now. She sat for a week before they ever touched it cause they were waiting on the parts. I told them no rush when I brought it in and to take their time and do a good job.

Speaking of parts....I called Mike at: http://eagle-m-e.com/index.html
on the Friday after T-day and ordered a doo-hickey and the 1" risers from him and they showed up on Monday! (California to Georgia) What great service on a Holiday weekend and what a great guy to deal with. I dropped the parts off at the dealer the next day.

Well, last Friday I stopped by on my way to work and my baby was in a million piece's! I really didn't need to see that but I wanted to check in on her. On the stand sat a frame, two wheels, and handle bars with a carb dangling. Next to her on the bench, my engine completly tore apart.
One good thing was I asked to see the stock doo-hickey and it was still intact and not broken. I also kinda quized the mechanic on a few things and he seemed like he knew what he was doing. Said he was still waiting on a few more gaskets but it wasn't holding him up for putting the engine back in. There was also another KLR in there getting the doo-hickey replaced with an aftermarket one so that kinda made me feel good too.

I'll probably be hearing from them this week and hopefully have her back. I'm gonna have to give her a thorough exam and inspection of their work and check all fasteners because I'm just anal like that!

We had some great weather this past week too and would have loved to got out for some riding! Now it's getting cold again. Oh well, as long as she's fixed right and running like before. I hope to make it down to Florida next month for the big ride.

On a side note, I scored an older 3 rail bike trailer last week for $75 off the Craigslist. It is a Holsclaw brand and just needs minor TLC but is useable as is and I drug her home 50 miles with no problems.
 

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Good news.Keep us posted.Ya,I have dealt with eagle mike in the past,great guy,supurb parts.
 

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Discussion Starter #12
An update to my saga....

First off, Merry Christmas to everybody!

I got my KLR back yesterday from the dealership! Can't wait to go for a ride but it's cold and rainy here today.
 

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An update to my saga....

First off, Merry Christmas to everybody!

I got my KLR back yesterday from the dealership! Can't wait to go for a ride but it's cold and rainy here today.
Rainy and cold, ya big wussy get out there man we wanna know how she runs out, grats on gettin her running again, have you put a skidplate on her yet????????
 

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Discussion Starter #15
I did putt around the yard today for a few minutes before work as it warmed up a little here today and stopped raining. I want to go over everything thouroughly before taking her out on the road and this damn job keeps interfering with that!

Negative on the skid plate...looking for one now or will fab one up myself.

No offroading until one is installed though, I promise! :18:
 
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