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Old 01-13-2012, 02:50 AM   #721
Ranger Rob
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Location: SE Queensland, AUSTRALIA
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Thanks Kojack

Thanks Kojack.

The bike has done a lot of KM but i'm hoping with a little love that it will keep going for a while.

I'm a KTM man, so what the hell is a "doo" spring and a "doohickey".

How much of a fix is that, and is it applicable for a 2008 model (purchased in 2007)
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Old 01-13-2012, 05:05 AM   #722
ddavidv
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Location: Elizabethtown, PA
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Quote:
Originally Posted by Ranger Rob View Post
Thanks Kojack.

I'm a KTM man, so what the hell is a "doo" spring and a "doohickey".

How much of a fix is that, and is it applicable for a 2008 model (purchased in 2007)
What it is: http://youtu.be/26oSOrvv_e8
Where you get it: http://www.eagle-m-e.com/productlist.htm
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Old 01-13-2012, 05:19 PM   #723
RevBill
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.. as I have an '06 I didn't pay close attention to it, but I believe the oil issue is a non-issue after 2008 (2009+) for the new bikes (Kawasaki changed the rings during the initial builds or something like that) ..

.. at least until you flog it into submission .. and then you can go with the new 688 (the 685 kit is being replaced I believe) or the 705 kit ..

.. great bikes .. love mine ..
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Old 01-13-2012, 05:30 PM   #724
CycleDoc59
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Joined: May 2006
Location: East Virginia
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Quote:
Originally Posted by kojack View Post
That is top gun. They make a bunch of different springs for the klr.

Sent from my ARCHOS 80G9 using Tapatalk
Yep, here's the website: http://www.topgunmotorcycles.com/KLR...lrsprings.html
I'm about 190# and tried the yellow spring, but soon found the white 7.4kg spring was just
right for me..
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Old 01-13-2012, 05:41 PM   #725
CycleDoc59
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Quote:
Originally Posted by BDXMPL View Post
My buddies '06 is making god awful noises. They started all of a sudden. One day it was fine, the next, it sounds like hammers in a blender. It has 8K on it.

Sounds just like this:



So far we've checked the doo-hickey, valves, KACR, clutch basket, piston, rings, wrist pin, and small end. All were in spec, and showed little sign of wear. Crank does not seem "loose".

I'm thinking it might be the mains, but I'm wondering if you guys could think of anything else it might be, before I split the cases.

Any ideas?

Hunter
When I had a 4 cyl bike come in making similar noise at low rpm, it turned out to be a bad
rod bearing. When I pulled off the head, one piston top was very clean, as was the head at that
cylinder. At low speed the the piston was smacking the head, and as rpm rose, there
was enough pressure in the cylinder to prevent the piston from contacting the head...
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Old 01-13-2012, 06:46 PM   #726
Ranger Rob
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Thanks.

Thanks guys for the links, advice and general help.

I feel like a KLR mechanic already and i don't even own one yet!

Rob
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Old 01-14-2012, 04:26 PM   #727
DirtyADV
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Location: SWEDEN, Skellefteå
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Quote:
Originally Posted by Ranger Rob View Post
Thanks guys for the links, advice and general help.

I feel like a KLR mechanic already and i don't even own one yet!

Rob
If you go for the new "doo" and the torsion spring make sure to still install the old lever to hold the needle bearing in place, I DIDN´T and the resulted in an unnecessary bearing failure! (go back a page or 2 to see the result)

And NOW this lever is going in place

Found another needle just laying there:

Hmm a needle just laying there

And found where all the metal shavings ended up, on the pickup, and another half needle there also, this explains why there was so little shavings in the filter:

A lot of shavings on the pickup and half a pin

Have started putting it back together and almost forgot the strainer:

Almost forgot the strainer

Can not fully find all pieces from the bearing, but have at least 18 of the 19 needles and some bits and pieces, hopefully its enough that I won't have any future problems!

What I could find from the bearing

/Johan
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Old 01-14-2012, 04:31 PM   #728
tommu56
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Location: limerick pa / waterville pa
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Quote:
Originally Posted by ausfahrt View Post
I recall a post somewhere about a company that will install stiffer springs on stock rear KLR shocks but I can't remember the name of the company. The stock shocks are optimized for a 160 pound rider and I tip the scales at about 250 before breakfast!

I haven't got that far yet but am looking at a set up by these guys as I am a little heaver than you.

sasquatch

tom
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Old 01-14-2012, 04:34 PM   #729
Ken
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I am the proud owner of a 2011 black/gray KLR
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Old 01-14-2012, 05:31 PM   #730
MotoBoss
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Quote:
Originally Posted by Ken View Post
I am the proud owner of a 2011 black/gray KLR

Congrats!..........................pics please
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Old 01-14-2012, 05:45 PM   #731
nakedwaterskier
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The 2008 had oil consumption and fire issues. Late 2008 the oil ring was redesigned to eliminate the oil consumption problem. The routing/protection of the battery/starter cables caused shorts/fires/burned wires.

I wouldn't buy an 08 unless it was a very late 08 or it had factory recalls done or a big bore kit. Running a high oil consumption engine--you are just asking for problems. Insulating the battery/starter cables is no biggie.

AS FAR AS ENGINE NOISE...MY 04 VIBRATED THEN BLEW AT 35K MILES BECAUSE I SPUN A BALANCER SHAFT BEARING despite doing the doohickey properly a long time ago. The counterweights are HEAVY!
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Old 01-14-2012, 08:23 PM   #732
Bobby C
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I have an 09 I bought new in Aug.of 2010 that burned a ridiculious amount of oil the first 4500 miles or so. I now have 9200 miles and have no problems. Maybe the engine has a drinking problem only during the break-in until it matures. I hope I don't see a relapse.
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Old 01-14-2012, 09:24 PM   #733
Bobby C
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I am on a very tight budget and have been considering the ammo cans for some time now.

Has anyone out there done this mod? I have a tutorial on the job saved on my favorites but what I really want to know is what options do I have as far as price is concerned for a mounting system.

The cheaper the better!

Keep in mind that I don't know how nor do I have the means to weld.

Thanks in advance!
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Old 01-15-2012, 09:20 AM   #734
willys OP
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If you can't weld or don't want to, you are screwed IMHO in means to build a solid rear pannier that won't vibrate loose while on an adventure IMHO. Save up the coin and buy either a good secondhand unit or buy the strongest on the market, a PackRat system. $250 iirc. Sorry. Also look for mermite boxes instead of those heavy ammo cans.....mermites are super light and do require a bit of work but you won't be sorry. I have a set and they are almost indestructable.
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Old 01-15-2012, 09:32 AM   #735
DirtyDog
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Quote:
Originally Posted by willys View Post
...mermites are super light and do require a bit of work but you won't be sorry. I have a set and they are almost indestructable.
I agree they are a good option (lightweight and caverous), but they are destructable. They are oversized tin cans, afterall. I was sorry to see mine permanently retired last summer.

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