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Old 02-01-2010, 08:21 PM   #61
ginn68
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Default Re: Potential ticking time bomb caught!

Has anyone seen in failures? I assume that's what Kawi will look at for a recall.

This is a major issue to add to the other open issues (i.e. oil burning, doo's, rubber, blinkers, and wiring harness) Fun stuff....I still wouldn't trade my KLR for anything.
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Old 02-04-2010, 07:43 PM   #62
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by ginn68 View Post
Has anyone seen in failures? I assume that's what Kawi will look at for a recall.

This is a major issue to add to the other open issues (i.e. oil burning, doo's, rubber, blinkers, and wiring harness) Fun stuff....I still wouldn't trade my KLR for anything.
I consider my first find a failure, the other preventing a catascopic failure
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Old 03-27-2010, 06:13 PM   #63
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Default Re: Potential ticking time bomb caught!

I just found this issue on my 09
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Old 03-27-2010, 06:27 PM   #64
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Default Re: Potential ticking time bomb caught!

Can anyone suggest what I should do. I found it by accident, searching for a lost shim from my first valve job. A special thanks to Yarddog for providing his knowledge and spare shims.

So should I talk to my dealer or make a shim?
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Old 03-27-2010, 06:51 PM   #65
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Default Re: Potential ticking time bomb caught!

Pull the gear out and take a pic of the other side and the cover.
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Old 03-27-2010, 06:55 PM   #66
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Default Re: Potential ticking time bomb caught!

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Pull the gear out and take a pic of the other side and the cover.
In the first pic that is the cover with the never ending hole. The engine side is fine, the shaft fits and stops where it should, the cover side the shaft goes in way to far.
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Old 03-27-2010, 07:13 PM   #67
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Default Re: Potential ticking time bomb caught!

Get a new side cover if the dealer will cough one up for free. Otherwise make a plug. BTW where is the other shim washer?
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Old 03-27-2010, 07:17 PM   #68
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Default Re: Potential ticking time bomb caught!

One on either side of the gear right???
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Old 03-27-2010, 07:20 PM   #69
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yes
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Old 03-27-2010, 07:27 PM   #70
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Default Re: Potential ticking time bomb caught!

I had the same on mine, the shaft had moved so far outboard that it was no longer supported on the engine side as can be seen by the gouging near the bush on the engine side.

I pulled the bearing bush in the outer case, fitted a 1/4" spacer into the case with a stainless washer on the shaft side and reinstalled the bush. Once fitted, the bush will stop the spacer and washer going anywhere and stops the shaft migrating outboard.


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Old 03-27-2010, 08:01 PM   #71
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Default Re: Potential ticking time bomb caught!

Thanks Hoyks, if its not worth a trip to the dealer then I need some measurements. OD and Length of a shim. But if its a known problem then lets get them to address it. EM, WW many others I'm sure, what to do.....
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Old 03-27-2010, 09:31 PM   #72
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Default Re: Potential ticking time bomb caught!

I think it has been addressed in later built bikes, the hole isn't bored as deep.

I just couldn't be bothered going into the dealer. It is too far, ends up as an argument and I leave fuming. I just get on with it.
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Old 03-27-2010, 09:59 PM   #73
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Default Re: Potential ticking time bomb caught!

I know your point, it just doesn't sit well with me. A problem that they just let go...

I would like some proper mesurements if they are available, please.
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Old 03-27-2010, 10:34 PM   #74
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Default Re: Potential ticking time bomb caught!

Glad I could help. It wouldn't hurt to discuss it with the service manager at the selling dealer. I e mailed you. Ken
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Old 03-28-2010, 01:14 AM   #75
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by rustynut View Post
I just found this issue on my 09

What was your date of manufacture? Trying to determine if my 09 may have the same issue without pulling the cover.
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Old 03-28-2010, 03:49 AM   #76
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by rustynut View Post
I would like some proper mesurements if they are available, please.
I used a aluminium standoff spacer (ally rod with a 5/32 hole up the middle) I had in the shed.
It was 3/8" wide x 1/4" and backed up with a 1/32" thick washer. Not certain on the washer size but it must be around the 3/8 - 1/2" mark. I just grabbed it out of the bits box and didn't pay that much attention.
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Old 03-28-2010, 08:12 AM   #77
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by PKZZR View Post
What was your date of manufacture? Trying to determine if my 09 may have the same issue without pulling the cover.
8/08
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Old 03-28-2010, 09:35 AM   #78
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Default Re: Potential ticking time bomb caught!

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Originally Posted by rustynut View Post
8/08
Mine was 10/08, too close not to pull the cover again (1st time doo) and check. My 12 months was up in December so I'll be making a spacer if it is a deep hole. Thanks.
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Old 03-28-2010, 10:28 AM   #79
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by PKZZR View Post
Mine was 10/08, too close not to pull the cover again (1st time doo) and check. My 12 months was up in December so I'll be making a spacer if it is a deep hole. Thanks.
I did the doo also and didn't see it. I guess I was lucky to drop a shim in the abyss while doing a valve shim job.
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Old 04-26-2010, 09:50 PM   #80
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Default Re: Potential ticking time bomb caught!

Just a friendly reminder to check your hole!

Last edited by bfine; 04-26-2010 at 09:54 PM.
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