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Search took 0.01 seconds. Search: Posts Made By: rectangular
Forum: Thumpers 03-18-2013, 11:16 PM
Replies: 124
Views: 10,876
Posted By rectangular
Talking Final day of the build!

Here we are, at the final build day of the KLR650! Let's get right into it…

Last time I stopped, I just got the head back on. Now, I'll have to finish buttoning that up, and get all the ancillary...
Forum: Thumpers 03-14-2013, 10:17 PM
Replies: 124
Views: 10,876
Posted By rectangular
Talking Finally, back at it!

Hey everyone! I'm finally back at the build. It took almost two months to get a head and some cams, but they arrived last week!

Time to get to work.

I think I have everything together to get...
Forum: Thumpers 02-06-2013, 02:00 PM
Replies: 124
Views: 10,876
Posted By rectangular
Interesting! It still seems like they could have...

Interesting! It still seems like they could have designed a better oil system perhaps. Wet sump seems like a bad idea when it comes to something that could end up running on it's side for brief...
Forum: Thumpers 01-29-2013, 08:57 AM
Replies: 124
Views: 10,876
Posted By rectangular
Glad that everyone agrees the oil pump is...

Glad that everyone agrees the oil pump is good-to-go! Now I'm basically just waiting on gaskets and my refreshed head from Eagle Mike.

I picked up some 10w40 non-synthetic castrol motorcycle oil...
Forum: Thumpers 01-28-2013, 10:13 PM
Replies: 124
Views: 10,876
Posted By rectangular
Oil pump pictures!

I had some spare time tonight to get in and look at the oil pump. It seems to me that it has some signs of wear, but I don't think it's to the point of affecting it's function. The surface feels...
Forum: Thumpers 01-28-2013, 03:18 PM
Replies: 124
Views: 10,876
Posted By rectangular
Nothing is wrong. Beezer mentioned above to put...

Nothing is wrong. Beezer mentioned above to put some punch marks in it. But, I think I'm going to pass on that. Pretty sure I would mess that up. :lol3
Forum: Thumpers 01-28-2013, 03:03 PM
Replies: 124
Views: 10,876
Posted By rectangular
I have some new copper gaskets for the banjo...

I have some new copper gaskets for the banjo bolts.

Sounds like using grease is the way to go so that gaskets can be reused. I like it!

I'm a little paranoid about modifying the woodruff key in...
Forum: Thumpers 01-28-2013, 02:59 PM
Replies: 124
Views: 10,876
Posted By rectangular
I didn't get a jug from Eagle Mike. There's a...

I didn't get a jug from Eagle Mike. There's a pretty awesome local motorcycle machine shop. I had them do all the machine work on the cylinder jug that came with my bike.
Forum: Thumpers 01-28-2013, 12:46 PM
Replies: 124
Views: 10,876
Posted By rectangular
On it! I should underline that step in the Clymer...

On it! I should underline that step in the Clymer manual.

I should have posted build threads like this ages ago. It's good to find out all the stuff I'm doing wrong. :rofl I don't have any actual...
Forum: Thumpers 01-28-2013, 11:20 AM
Replies: 124
Views: 10,876
Posted By rectangular
Yeah. I'm a little slow today. I figured out...

Yeah. I'm a little slow today.

I figured out what was going on once I started looking up pictures of the oil pump. :lol3
Forum: Thumpers 01-28-2013, 10:58 AM
Replies: 124
Views: 10,876
Posted By rectangular
Edit: Nevermind, the oil pump is phillips head. I...

Edit: Nevermind, the oil pump is phillips head. I follow now. :D

Also, I'm probably going to be going in and checking on the oil pump tonight. Anything specific that I should look for once I...
Forum: Thumpers 01-28-2013, 10:06 AM
Replies: 124
Views: 10,876
Posted By rectangular
I don't have a hand impact driver :( ...

I don't have a hand impact driver :(




And it won't cause issues with coolant leaking? Interesting. I might have to give this a shot.

Also, I haven't found a definitive answer if the side...
Forum: Thumpers 01-28-2013, 08:56 AM
Replies: 124
Views: 10,876
Posted By rectangular
Will do. It shouldn't take very long anyways. I'm...

Will do. It shouldn't take very long anyways. I'm getting pretty familiar with both sides under the engine covers.
Forum: Thumpers 01-27-2013, 10:51 PM
Replies: 124
Views: 10,876
Posted By rectangular
I see! Yeah, that does actually seem like a lot...

I see! Yeah, that does actually seem like a lot better way to remove or install. Keeps it nice and even, much less chance of it getting jammed. I'll have to remember that next time I have to install...
Forum: Thumpers 01-27-2013, 09:11 PM
Replies: 124
Views: 10,876
Posted By rectangular
Ahhh... crap. Is this something I can defer...

Ahhh... crap.

Is this something I can defer to after my 20-minute break in? I'll be checking the oil screen at that point too.

(I think I already know the answer to this...)
Forum: Thumpers 01-27-2013, 08:42 PM
Replies: 124
Views: 10,876
Posted By rectangular
I'm not sure I follow. That was the old seal that...

I'm not sure I follow. That was the old seal that we had to drive out. It's the way the Clymer manual specifically described removing the old seal. We ended up punching a hole through the old one...
Forum: Thumpers 01-27-2013, 05:47 PM
Replies: 124
Views: 10,876
Posted By rectangular
Ahh, yup! You're right. I remembered that on the...

Ahh, yup! You're right. I remembered that on the reinstall but forgot about it when I wrote it up. The shortest one is on the far left.
Forum: Thumpers 01-27-2013, 04:00 PM
Replies: 124
Views: 10,876
Posted By rectangular
Day 5 of the Rebuild!

I was not mentally ready to deal with engine case yet, so we moved on to getting the right side of the engine wrapped up.

A little bit of kerosine to clean up the gasket surface.
...
Forum: Thumpers 01-27-2013, 03:59 PM
Replies: 124
Views: 10,876
Posted By rectangular
Continued...

After the cylinder was in, it was time to return to finishing up the doohickey. Consequently, this is where things soon went pear shaped.

The new rotor bolt, ready to be installed.
...
Forum: Thumpers 01-27-2013, 03:58 PM
Replies: 124
Views: 10,876
Posted By rectangular
Moar!

More glamour shots.

http://static.geofcrowl.com/klr4/klr-day4-37.jpg

I kept getting distracted and taking photos of the newly bored cylinder.

http://static.geofcrowl.com/klr4/klr-day4-38.jpg...
Forum: Thumpers 01-27-2013, 03:57 PM
Replies: 124
Views: 10,876
Posted By rectangular
Continued...

Looks like it's a stock doohickey.

http://static.geofcrowl.com/klr4/klr-day4-20.jpg

http://static.geofcrowl.com/klr4/klr-day4-21.jpg

Here's some comparisons between stock and the Eagle Mike...
Forum: Thumpers 01-27-2013, 03:57 PM
Replies: 124
Views: 10,876
Posted By rectangular
Day 5 of the Rebuild!

Continuing on with the build journal.

First order of the day was to start taking care of some cleaning. The rat's nest below the starter was not kosher.

Definitely seems like some oil has been...
Forum: Thumpers 01-27-2013, 10:54 AM
Replies: 124
Views: 10,876
Posted By rectangular
Good news!

I was able to clean up the starter rotor and block block fairly well with the help of a friend. On first glance, the starter rotor looks new and with some mild smoothing out, the block doesn't look...
Forum: Thumpers 01-26-2013, 03:52 PM
Replies: 124
Views: 10,876
Posted By rectangular
Ok. That doesn't sound too bad. I'm still curious...

Ok. That doesn't sound too bad. I'm still curious why Kawasaki spot welded that toothed bit on the back. Seems rather strange.

The cam chain seems fine from a visual inspection. It doesn't seem...
Forum: Thumpers 01-26-2013, 01:05 PM
Replies: 124
Views: 10,876
Posted By rectangular
Well... shat... that's a problem.

Well... ran into a bit of a snag today. I got the cylinder back from the machine shop, got the new piston and cylinder installed. I also got the new doohickey installed as well with the torsion...
Forum: Thumpers 01-25-2013, 01:11 PM
Replies: 124
Views: 10,876
Posted By rectangular
Quick question for anyone who has been following...

Quick question for anyone who has been following my thread: what oil would anyone recommend for my engine break in? I've used rotella 30W for car engines, but I'm unsure about motorcycles. I'm not...
Forum: Thumpers 01-22-2013, 02:01 PM
Replies: 124
Views: 10,876
Posted By rectangular
Thanks! Glad everyone is enjoying this. I'm...

Thanks! Glad everyone is enjoying this.

I'm not sure I'm familiar with the $.22 fix for the carb. Can someone enlighten me? :D


Update: I got all of the parts in from Eagle Mike except for the...
Forum: Thumpers 01-20-2013, 09:12 PM
Replies: 124
Views: 10,876
Posted By rectangular
The 685 kit is probably the better route to go in...

The 685 kit is probably the better route to go in the long run. The 688 kit is really only made to be used when your 685 wears out. Unfortunately the 685 kit is backordered temporarily and I'm kind...
Forum: Thumpers 01-20-2013, 08:56 PM
Replies: 124
Views: 10,876
Posted By rectangular
Great suggestions! I noticed the arrows on the...

Great suggestions! I noticed the arrows on the cam caps didn't seem to be pointing the right direction when I was taking it apart. I wasn't sure at what point they were set that way. I remember the...
Forum: Thumpers 01-20-2013, 10:03 AM
Replies: 124
Views: 10,876
Posted By rectangular
Wow! Worse? Does this happen at the factory?...

Wow! Worse? Does this happen at the factory? That's just mind boggling if that's the case.

I've heard that these engines are supposedly bulletproof, but I'm sure finding a lot of bullets. Ha.
Forum: Thumpers 01-20-2013, 09:51 AM
Replies: 124
Views: 10,876
Posted By rectangular
Question Interesting! I'll make sure to check that. Is...

Interesting! I'll make sure to check that. Is that behind the left side engine case cover? The same side as the stator?
Forum: Thumpers 01-19-2013, 11:06 PM
Replies: 124
Views: 10,876
Posted By rectangular
Question Day 3 of the rebuild! Interesting surprise today...

Finally! Here we are again. I have the majority of parts I need on their way from Eagle Mike. It's time for me to get the bike ready and prepared for the parts before they arrive.

This is the bike...
Forum: Thumpers 01-16-2013, 05:18 PM
Replies: 124
Views: 10,876
Posted By rectangular
Parts are all ordered up! Should be on their way...

Parts are all ordered up! Should be on their way in the next couple of days.

It's been a little bit of the waiting game recently. Between waiting for parts to arrive, and waiting for this cold...
Forum: Thumpers 01-14-2013, 03:22 PM
Replies: 124
Views: 10,876
Posted By rectangular
Just called Eagle Mike. He does in fact have a...

Just called Eagle Mike. He does in fact have a used head and cams on hand that he's going to machine up. I'll also be ordering up a 688 piston kit from him tomorrow (the 685 kits are out of stock)...
Forum: Thumpers 01-13-2013, 05:59 PM
Replies: 124
Views: 10,876
Posted By rectangular
Awesome! Sounds like Eagle Mike is a good...

Awesome! Sounds like Eagle Mike is a good community supporter. I'm leaning that way right now.
Forum: Thumpers 01-13-2013, 05:51 PM
Replies: 124
Views: 10,876
Posted By rectangular
Question Quick question for everyone, do people generally...

Quick question for everyone, do people generally prefer the 685 kit from Eagle Mike or Schnitz Racing? Anyone with first hand experience with either?
Forum: Thumpers 01-11-2013, 08:37 AM
Replies: 124
Views: 10,876
Posted By rectangular
Awesome! Bookmarking. I had to take last...

Awesome! Bookmarking.

I had to take last night off from working on the bike. I have had a little bit of a cold. Tomorrow I'm going to work on getting the jug off for inspection. There might be...
Forum: Thumpers 01-10-2013, 07:40 PM
Replies: 124
Views: 10,876
Posted By rectangular
If I can find a good head on ebay for a decent...

If I can find a good head on ebay for a decent price, I might just spring for the 685 kit. Everyone here is slowly convincing me of it! It would be a huge bummer to reassemble the bike and find out...
Forum: Thumpers 01-09-2013, 11:55 PM
Replies: 124
Views: 10,876
Posted By rectangular
Here we are! Day 2 of the build already. I made a...

Here we are! Day 2 of the build already. I made a lot of good progress in a little over two hours tonight. There's lots of images (Around 80 in total), so please be patient!

After seeing the...
Forum: Thumpers 01-09-2013, 10:48 PM
Replies: 124
Views: 10,876
Posted By rectangular
Thanks for all the good advice! I'm well used to...

Thanks for all the good advice! I'm well used to switching phillips with allen bolts. I have a 1975 Kawasaki KZ400 that I'm rebuilding from the ground up as well. Phillips heads everywhere! Drives me...
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