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Old 07-15-2009, 03:33 AM   #21
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Default Re: Potential ticking time bomb caught!

Ginn68 , Just curious, with the knowledge of this post while your bike was on the operating table why not just space it out?
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Old 07-15-2009, 10:09 PM   #22
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Default Re: Potential ticking time bomb caught!

Bfine: I didn't know about the post till after the fact. My luck.

Anyways, did the doo of my friends 09' tonight. Looks good on his case. I am leaning to the condition progresses with mileage. His bike has 1K and mine has 14K.
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Old 07-15-2009, 10:38 PM   #23
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Default Re: Potential ticking time bomb caught!

So did you put a spacer in the 09? to prevent it from walking over? now that you know?
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Old 07-16-2009, 12:39 AM   #24
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by ginn68 View Post
I am leaning to the condition progresses with mileage. His bike has 1K and mine has 14K.
I know we're early in the diagnosis, but I'm thinking it's a machining error. We're talking a .350 inch error, not a .002 inch error. The gears are only turning when you're holding in the starter button so I'm not thinking this is a "wear" thing.

Just my opinion at present.
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Old 07-16-2009, 03:29 AM   #25
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Default Re: Potential ticking time bomb caught!

Machining error or wrong bushing. I think there should be a hat bushing in there to limit the travel of the shaft. I know this is a stupid observation but when on the stand it aggravates the situation. I think the fix is to lean the bike to the right five minutes after any ride while idling. it will be in the 2010 operators manual. hahahhahaha (that was a joke)
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Old 07-17-2009, 02:30 PM   #26
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Default Re: Potential ticking time bomb caught!

All that was holding mine in the corect position was suction after incerting it into the inner case the last time I had it apart, on mine it was quite stuck.
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Old 07-23-2009, 06:14 PM   #27
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Default Re: Potential ticking time bomb caught!

No love on this thread??? I just pulled my 08 apart today and found the same issue. A slight amount of wear on the engine side and some good gouging on the case side. Nothing irreparable but I can definitely see this being an issue on the 08 and up bikes. I used a 10 x 1.25 partial threaded bolt and trimmed a section of the unthreaded portion down to about .310". This leaves me about .10" left for shaft wiggle room. Then slid it in and noticed the spacer sleeve and the fact that where the spacer sits is wider. Doh. I then injected a small amount of Black RTV, pushed the spacer in, centered it and cleared away the excess. I'll let it cure overnight and it should keep it from rattling around in there. Let me know if you think I tarded anything up.
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Old 07-24-2009, 10:57 AM   #28
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Default Re: Potential ticking time bomb caught!

Bump!!
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Old 07-24-2009, 11:08 AM   #29
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Default Re: Potential ticking time bomb caught!

Measure the shaft length. I've measured several here and all are 42.6mm. I've never seen this condition in any bike I worked on, including a lot of 2008 and 2009 models.
all the best,
Mike

Edited: I was wrong about this. I'm in full agreement that there is an issue
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Old 07-24-2009, 11:47 AM   #30
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Default Re: Potential ticking time bomb caught!

i would concur with EagleMike and Watt-Man...shaft is correct and the depth of the hole is incorrect...

BUT...i will keep my eyes pealed on the next five 685s/doohickies in the queue...

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Old 07-24-2009, 01:17 PM   #31
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by Eaglemike View Post
Measure the shaft length. I've measured several here and all are 42.6mm. I've never seen this condition in any bike I worked on, including a lot of 2008 and 2009 models.
all the best,
Mike
I measured mine while it was out and got 42.598mm. The starter reduction gears stayed on the engine when the case came off and I didn't notice anything amiss until I removed them. I also had to remove the spacer bushing in the case to see the wear behind it.
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Old 07-24-2009, 07:09 PM   #32
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Default Re: Potential ticking time bomb caught!

I just did the doo on my 2009 and post here a picture showing how the factory must have addressed the problem. Notice there is a positive stop to keep the shaft from migrating?

Erik
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Old 07-25-2009, 08:17 AM   #33
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Default Re: Potential ticking time bomb caught!

So can I expect my recall notice from MamaKaw any day now? I still haven't received their Doo recall notice yet but I'm sure it's just lost in the mail somewhere. :-)

(bump to the attention-space at top)

"Sticky" worthy?
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Old 07-25-2009, 10:28 PM   #34
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by B12se View Post
I just did the doo on my 2009 and post here a picture showing how the factory must have addressed the problem. Notice there is a positive stop to keep the shaft from migrating?

Erik
Erik, from your picture I cant tell if the second hole down has the same Cast in stop, I am on tour now and cant look at the bike. But if I recall it's the second hole down the idler shaft sits in.I see the one for the torque limiter gears? are they all the same?


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Old 07-26-2009, 08:36 AM   #35
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Default Re: Potential ticking time bomb caught!

Bryan,
Yes both holes are the same. They both have stops in the casting. What makes it hard to see in the second hole is the moly grease they put in there.
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Old 07-29-2009, 07:10 PM   #36
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Default Re: Potential ticking time bomb caught!

No update from Kawi yet. I will follow up.
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Old 08-08-2009, 08:08 AM   #37
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Default Re: Potential ticking time bomb caught!

I received a reply from Kawi,

They are aware of the problem, The problem being the case was drilled to deep,

The good news.

They will repair any damaged parts with new, within warranty or not, This bike is out of warranty.

The were interested in my VIN numbers and what bikes I own are infected with the deep hole h1n5 flu.

If I were planing a long trip, I would make sure you check this prior to take off!

As you seen from my pictures mine was about to give way and cause more problems than a suicide bomber.

So there you go.

Ride-on,

Bryan

P.S. thanks to Kawi for addressing the issue and standing behind their product!
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Old 08-08-2009, 09:04 AM   #38
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Default Re: Potential ticking time bomb caught!

Great News. The problem is my local kawi dealer doesn't always follow through with Kawi. How would you suggest handling this? Should I contact Kawi first? Also, should I mention I noticed this because I was doing the Doo mod?

Thanks for all your help.
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Old 08-08-2009, 09:25 AM   #39
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Default Re: Potential ticking time bomb caught!

Can you guys post what year your bikes are.
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Old 08-08-2009, 08:47 PM   #40
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by ginn68 View Post
Great News. The problem is my local kawi dealer doesn't always follow through with Kawi. How would you suggest handling this? Should I contact Kawi first? Also, should I mention I noticed this because I was doing the Doo mod?

Thanks for all your help.
Ginn

If you already inspected your bike, and your KLR is infected with the H1N5 deep hole flu. I would first report it to your dealer, Saying you read this on a forum, and inspected the bike, and found you were infected. Suggest if they have any questions to contact Kawi Tech line.

In my case I will inspect my other bikes and since I have the cover off and if I dont see any damage,I will space it out with a suitable ball bearing or some sort of spacer to fill the gap and call it good, and not bother with Kawasaki.

The one I spaced out with the spring as a temporary fix has went 2000 miles with no further relapse of the H1N5 deephole flu or further complications. Because there was wear damage I will replace the warn parts.


Ride-on

Bryan
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