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Old 04-26-2010, 10:03 PM   #81
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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.
It only takes a few minutes to pull the outer cover and make sure, its sure does give you a peace of mind, knowing your starter idler gear wont fall into other parts rotating at up to 7500 RPM!
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Old 05-09-2010, 10:44 PM   #82
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Default Re: Potential ticking time bomb caught!

Finally got around to checking my hole today and it was a deep one! Used a 3/8" x 3/8" set screw I had laying around for the spacer. Peace of mind!
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Old 05-09-2010, 11:14 PM   #83
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Default Re: Potential ticking time bomb caught!

I would like some proper mesurements if they are available, please.[/quote]

My measurements were .393" dia shaft, depth of shaft sticking out when bottomed in the engine side was .336", depth of hole in side cover was .750". So, I had .414" too much depth in the side cover hole. I used a .373 diameter x .372 long set screw (3/8" x 3/8") with a dab of grease to hold it in. This gives me .020 clear in the diameter and about .040 clear on the length to allow for any heat expansion.
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Old 05-15-2010, 09:48 PM   #84
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Default Re: Potential ticking time bomb caught!

Help do the doo on an 08 today and found another deep holer. Build date was 7/07.

Added the spacer provided by Eagle MIke (kudos). All is well.
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Old 05-15-2010, 10:29 PM   #85
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Default Re: Potential ticking time bomb caught!

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Originally Posted by jj ski View Post
Help do the doo on an 08 today and found another deep holer. Build date was 7/07.

Added the spacer provided by Eagle MIke (kudos). All is well.
yes that was on my 08 the red tank, Thanks JJ Ski! Thanks Eagle Mike! Hole of Death patched now on to the Weeping Oil Syndrome.
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Old 05-23-2010, 12:33 AM   #86
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by bfine View Post
It only takes a few minutes to pull the outer cover and make sure, its sure does give you a peace of mind, knowing your starter idler gear wont fall into other parts rotating at up to 7500 RPM!

Checked mine tonight. NO deep holes. MFR 10/08 for a bench mark for others.
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Old 05-31-2010, 11:28 AM   #87
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Default Re: Potential ticking time bomb caught!

Is Eagle Mike making a repair kit for this now? My 08 started making the starter clunk last summer, I've been riding my DR650 lately so I haven't ridden the KLR much. (And I've been away from this forum for a while.)

Guess I'm gonna have to take it apart and have a look.
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Old 05-31-2010, 07:50 PM   #88
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Default Re: Potential ticking time bomb caught!

Well, I just checked my 2009 KLR - build date Sept 2008 - and it has the deep hole problem. No damage yet. I just bought it (used) 3 weeks ago with 706 miles on it. I've got it up to 851 now. Left outer case has the hole bored to .750 inch with no step. I used the 3/8 by 3/8 setscrew as a shim as mentioned in an earlier post. Unfortunately, since this is memorial day, I had no new gasket and no place to get one that would be open. So, I just put it back with the old one, and, suprise, it has an oil drip now...Groan!

I'll talk to the local Kawasaki dealer tomorrow and see if they can get this fixed for me at no cost. If not, I'll be getting a gasket and having the joy of another R&R of the outer case.

I don't think any sealer is used on the gasket. Am I right about that? And Thanks bfine and everyone for reporting this. I shall see if Kawasaki will take care of this (as they should) or not.
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Old 05-31-2010, 11:00 PM   #89
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Default Re: Potential ticking time bomb caught!

I'm not sure on the klr but on my ex500 you could use high temp rvt gasket sealant for all gaskets (ie no gasket just rvt) except the head gasket with no problem. I don't see why it wouldn't work on the klr
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Old 06-01-2010, 09:28 AM   #90
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Default Re: reusing the gasket

Quote:
Originally Posted by klrbug View Post

I don't think any sealer is used on the gasket. Am I right about that? And Thanks bfine and everyone for reporting this. I shall see if Kawasaki will take care of this (as they should) or not.
There did not appear to be any sealer on my 08. But the gasket does appear to be "goopy" for lake of a technical word. It leaves behind a silver residue. We DID NOT scrape any of that away hoping that would recreate the exact seal when reusing the gasket. It seems to have worked I haven't seen a leak yet.
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'08 KLR Red (the fast one?) thermo-bobbed, doo-hickeed, .22 cented, deep hole plugged, To do... fix hard start << $400 @ the dealer made it worse, weep hole leak and oil be gone.

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Usually I can f**k up an anvil with a rubber mallet. - rtwdoug
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Old 06-01-2010, 01:40 PM   #91
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Default Re: Potential ticking time bomb caught!

I stopped by the dealer this morning, they took all my info and will be calling Kawasaki today sometime.

Whatever. . .

It did the starter clunk in the dealer's parking lot, I think I'm not gonna ride this thing til I can get in the side cover an fix the problem. This is not good & I can't afford to fix catastrophic damage, so a little preventive maintenance is on order.
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Old 06-01-2010, 09:16 PM   #92
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Default Re: reusing the gasket

Quote:
Checked mine tonight. NO deep holes. MFR 10/08 for a bench mark for others.
Checked my '09s build date tonight, it too was built in 10/08. Hopefully it's good, I do not have the wherewithal to get mine checked right now.
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Old 06-01-2010, 10:04 PM   #93
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Default Re: reusing the gasket

Quote:
Originally Posted by neviander View Post
Checked my '09s build date tonight, it too was built in 10/08. Hopefully it's good, I do not have the wherewithal to get mine checked right now.
Mine has the deep hole at 8/08, I wouldn't take the chance. Remove the shifter, remove the outer cover bolts, and dump the oil. There will be 2 starter gears on 2 shafts with a total of 4 washers. 1 washer on each side of the gear, the gears only go on 1 way. Its klr owner proof, almost. If your missing parts then they fell against the flywheel/rotor. It sounds harder than it is. I think its an 8mm socket, 8mm wrench and a 10mm socket.
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Old 06-02-2010, 12:17 PM   #94
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Default Re: Potential ticking time bomb caught!

Did mine with the doo.
Build date 8/08.
HUGE difference.
Used 3 stainless washers by the seat of my pants.

Very easy fix, and very necessary; it really looked like hell on the inside bearing.

I'd call for a recall, but F--- the man.
This is something that needs to be well documented, and used as a leverage point on the OTD for the new recruits.
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Old 06-02-2010, 12:32 PM   #95
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by stolentino View Post
Did mine with the doo.
Build date 8/08.
HUGE difference.
Used 3 stainless washers by the seat of my pants.

Very easy fix, and very necessary; it really looked like hell on the inside bearing.

I'd call for a recall, but F--- the man.
This is something that needs to be well documented, and used as a leverage point on the OTD for the new recruits.
It's an easy fix, I'd probably not even break a sweat doing the repair (But then I live in Tucson and break a sweat putting on my glasses in the morning.)

I've filed a complaint with Kawasaki consumer services (ph. 949-468-5688) and I've been to the dealer to see if they'll cover the repair, even out of warranty. If they won't, I'll do the job myself. It's the old refrain, "But I shouldn't have to fix this." The mantra of the 08 KLR owner. You do the repairs, because the alternative is catastrophic failure. Same with the doo, and even the oil consumption issues.

I like my KLR okay, but I wouldn't buy another. In the meantime, just another reason to put miles on the ancient and beatup DR650--takes a lickin' keeps on tickin'.
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Old 06-02-2010, 04:45 PM   #96
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Thumbs down update

I got the word from the local dealer. Kawasaki doesn't stand behind their product past the end of the warranty and won't cover this defect.

So I guess I'll go out an start fixing my bike.

As someone recently said, "F*** 'em."
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Last edited by Good Times; 06-02-2010 at 04:50 PM.
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Old 06-03-2010, 01:29 PM   #97
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Default Re: Potential ticking time bomb caught!

Thanks to all for the info. My 2008 (built 06/07) has started making a grinding noise during startup, that was not there originally. I plan to find a bearing ball that fits, and green Locktite it in place. Should be a no brainer. I wish I had caught it when I did the doo, or at least when I reopended the case to find the doo idler shim that dropped out when I did the doo!

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Old 06-03-2010, 10:57 PM   #98
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Default Re: Potential ticking time bomb caught!

Quote:
Its klr owner proof, almost. If your missing parts then they fell against the flywheel/rotor. It sounds harder than it is. I think its an 8mm socket, 8mm wrench and a 10mm socket.
Question, if I do this simple check, will I possibly need new gaskets? I'll get some, if so.
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Old 06-03-2010, 11:35 PM   #99
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Default Re: Potential ticking time bomb caught!

Quote:
Originally Posted by neviander View Post
Question, if I do this simple check, will I possibly need new gaskets? I'll get some, if so.
I did mine yesterday and didn't need a gasket. You may need a new gasket for between the engine sidecover and the case tho.

I posted up on this problem on ADV, check out the second post in the thread!!! https://www.the.com/forums/showthread...1#post13106711
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Old 06-04-2010, 02:13 PM   #100
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Default Re: Potential ticking time bomb caught!

If you found this problem in your KLR, let the NHTSA know. The form is very short, but this is a safety issue and Kaw should be made to fix in a recall.https://www-odi.nhtsa.dot.gov/
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