Kawasaki KLR Forum banner

1 - 11 of 11 Posts

·
Registered
Joined
·
757 Posts
Discussion Starter #1 (Edited)
The first time I did this, I fixed it myself with some mods at around 13,000 miles. Now I have over 36,000 miles and it started doing it again. Since most of us use this as a fuel gauge, it's worth it. This second time though, there was a lot of dust in there from all of my off road riding, so clean it out.

You really need compressed air to do this, or a couple of cans of that keyboard cleaner.

1. Remove the front fairing and set aside.





2. Remove the cluster from the frame mounts with three screws going thru rubber mounts. Disconnect the speedo cable. Get a place to work on it.

3. Remove the front bezel from the cluster.


4. Remove all the screws on the wires going to the gauges, the two screws holding the speedometer in, now lift the face with gauges out of the cluster housing.



5. Hold the back of the speedometer, push the reset rod and see how it works, and see where it is sticking. There will likely be a sharp edge on the plastic lever that gets pushed by the plastic plate.

6. Using a Dremel Tool or file/sand paper/Exacto knife/razor blade/whatever you have, grind down the edge to a radius. Clean off the filings!



7. I used silicone spray to lube the trip number wheels on the shaft, but use some sort of dry lube, then blow off the excess.



8. Lube the contact points of the lever & plate with a silicone lube, or light grease.



9. TEST IT!!!! Make sure that it resets easy a couple of times by releasing the lock and rotating the number wheels. Lift the lever you ground off halfway and that should release the numbers, and then use a small screw driver to rotate them.


10. Clean the face of the speedo off with a soft cloth.
11. Reassemble everything and take it for a test ride.

I added some stupid farlkes to my speedo face. I should have put the wobbles at 85 though.



Hope it helps, and see you out on the trails.
 

·
Premium Member
Joined
·
5,483 Posts
Nice writeup, campfire. Thanks. Just as you said, it's not just a tripmeter, it's a gas gauge. I call for permanent enshrinement in the "Common Mods And Issues" thread.
 

·
Administrator
Joined
·
8,304 Posts
I agree, a very nice job campfire!

It's been added.

Tom
 

·
Registered
Joined
·
191 Posts
Thanks for taking the time to photograph and document the process. I don't have a problem with mine but I'll now know where to look if I do.
Well done!

iddy
 

·
Registered
Joined
·
5 Posts
New cam

Attack of the Zombie thread.

I got too ambitious polishing and ate away too much of the lever. Instead, I made a replacement cam out of copper sheet with a longer lever. I polished the contact surface very well before lubing with Teflon spray. Works great now. Snapped a picture but I don't think I can link yet.



 

·
Registered
Joined
·
757 Posts
Discussion Starter #8
Excellent idea!
I have a chunk of aluminum sitting here that I'm saving if that thing ever goes out again after seeing your post. Thanks.

Cracked over 54,000 miles this summer on trips and it's still working good.
 

·
Registered
Joined
·
757 Posts
Discussion Starter #9
So I don't know what happened with the all of the links to the photo's. And I can't seem to edit the original post, but, if you click on the "Thread Tools" button located in the threads header bar, and then click "Printable Version", all of the picture hyper links show up.

Maybe Tom could throw in some advice.
 

·
Registered
Joined
·
757 Posts
Discussion Starter #10
Re-submitted with a different format, hope this works.

1. Remove the front fairing and set aside.

http://imagizer.imageshack.us/v2/xq90/174/742e9c.jpg


2. Remove the cluster from the frame mounts with three screws going thru rubber mounts. Disconnect the speedo cable. Get a place to work on it.

3. Remove the front bezel from the cluster.
http://imagizer.imageshack.us/v2/xq90/829/1cd74a.jpg

4. Remove all the screws on the wires going to the gauges, the two screws holding the speedometer in, now lift the face with gauges out of the cluster housing.

http://imagizer.imageshack.us/v2/xq90/807/35ac76.jpg

5. Hold the back of the speedometer, push the reset rod and see how it works, and see where it is sticking. There will likely be a sharp edge on the plastic lever that gets pushed by the plastic plate.

6. Using a Dremel Tool or file/sand paper/Exacto knife/razor blade/whatever you have, grind down the edge to a radius. Clean off the filings!

http://imagizer.imageshack.us/v2/xq90/195/b17e31.jpg

7. I used silicone spray to lube the trip number wheels on the shaft, but use some sort of dry lube, then blow off the excess.

http://imagizer.imageshack.us/v2/xq90/810/879128.jpg

8. Lube the contact points of the lever & plate with a silicone lube, or light grease.

http://imagizer.imageshack.us/v2/xq90/550/15f0cd.jpg

9. TEST IT!!!! Make sure that it resets easy a couple of times by releasing the lock and rotating the number wheels. Lift the lever you ground off halfway and that should release the numbers, and then use a small screw driver to rotate them.


10. Clean the face of the speedo off with a soft cloth.
11. Reassemble everything and take it for a test ride.

I added some stupid farlkes to my speedo face. I should have put the wobbles at 85 though.
http://imagizer.imageshack.us/v2/xq90/201/61f4cf.jpg
 

·
Registered
Joined
·
757 Posts
Discussion Starter #11
RE-SUBMITTED to correct missing pictures.
(Thanks for the PM Matt!)

The first time I did this, I fixed it myself with some mods at around 13,000 miles. Now I have over 36,000 miles and it started doing it again. Since most of us use this as a fuel gauge, it's worth it. This second time though, there was a lot of dust in there from all of my off road riding, so clean it out.

You really need compressed air to do this, or a couple of cans of that keyboard cleaner.

1. Remove the front fairing and set aside.



2. Remove the cluster from the frame mounts with three screws going thru rubber mounts. Disconnect the speedo cable. Get a place to work on it.

3. Remove the front bezel from the cluster.



4. Remove all the screws on the wires going to the gauges, the two screws holding the speedometer in, now lift the face with gauges out of the cluster housing.



5. Hold the back of the speedometer, push the reset rod and see how it works, and see where it is sticking. There will likely be a sharp edge on the plastic lever that gets pushed by the plastic plate.

6. Using a Dremel Tool or file/sand paper/Exacto knife/razor blade/whatever you have, grind down the edge to a radius. Clean off the filings!



7. I used silicone spray to lube the trip number wheels on the shaft, but use some sort of dry lube, then blow off the excess.



8. Lube the contact points of the lever & plate with a silicone lube, or light grease.



9. TEST IT!!!! Make sure that it resets easy a couple of times by releasing the lock and rotating the number wheels. Lift the lever you ground off halfway and that should release the numbers, and then use a small screw driver to rotate them.


10. Clean the face of the speedo off with a soft cloth.
11. Reassemble everything and take it for a test ride.

I added some stupid farlkes to my speedo face. I should have put the wobbles at 85 though.



Hope it helps, and see you out on the trails.
 
1 - 11 of 11 Posts
Top