KLR650 Only Thread......

Discussion in 'Thumpers' started by willys, Nov 19, 2011.

  1. newcastleadam

    newcastleadam Artful Tagger

    Joined:
    Oct 14, 2007
    Oddometer:
    3,455
    Location:
    Gainesville, Fl
    Changing fork seals to get my project 1993 KLR ready for sale, and the leaky one ain't budging with 120 psi in it. Gonna wait it out, then find something with a 24mm or 15/16" end to fully disassemble. Saw one guy made a universal holder out of a 1x1 piece of wood, sharpened like a tent stake to wedge onto the damper rod top. So there's that option :evil

    The non-leaky one popped fine of course :D.
  2. Hatley Rocket

    Hatley Rocket Been here awhile

    Joined:
    Feb 24, 2002
    Oddometer:
    357
    Location:
    Hatley, WI
    When I did the forks on my '01 concours, I believe the trick was to get some 5/8" threaded rod, like 24" or so long, with double nuts jammed against each other on each end. The 5/8" nut will give you your 15/16" end, as long as you get a standard nut, don't get X-tra heavy nuts. Use a 15/16" wrench on one end to hold the rod still, and the other jammed nuts fit into your damper rod. I hope it helps.

    T
  3. newcastleadam

    newcastleadam Artful Tagger

    Joined:
    Oct 14, 2007
    Oddometer:
    3,455
    Location:
    Gainesville, Fl
    Was able to pick the dust seal out, then nicked the oil seal enough to allow the air pressure to pop it. :evil
  4. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,292
    Location:
    Tulsa... it's OK
    Yes, mine was black like that.
  5. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,292
    Location:
    Tulsa... it's OK
    Next time, keep it pressured up and warm the fork lower with a gentle torch. It'll pop.

    Wrap a rag around the seal so you don't make a mess.

    Worked for me.
  6. ADW

    ADW 'tard bike restos

    Joined:
    May 29, 2009
    Oddometer:
    579
    Location:
    MI
    Agreed, was gonna suggest that as well. I use a heat gun. Heat on the area of the fork where the seal is located really helps loosen up the "grip" that the seal rubber has on the ID of the fork tube. Works every time.
  7. newcastleadam

    newcastleadam Artful Tagger

    Joined:
    Oct 14, 2007
    Oddometer:
    3,455
    Location:
    Gainesville, Fl
    Good tip. I did wrap the seal in a rag, mama didn't raise no fool :D
  8. bomber60015

    bomber60015 Anatomically Correct

    Joined:
    Sep 11, 2008
    Oddometer:
    15,175
    Location:
    Chicago-ish

    Got it - makes sense . . . . . .thanks!

    Ilearned something today -- must be time for a nap.
  9. IDRIDR

    IDRIDR Take me to the River

    Joined:
    Jun 16, 2010
    Oddometer:
    1,575
    Location:
    Boise, Idaho
  10. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    3,730
    Location:
    Garden City, Michigan
  11. Scott_PDX

    Scott_PDX Leisure Engineer

    Joined:
    Oct 18, 2010
    Oddometer:
    3,867
    Location:
    Portland...the newer one on the left side.
    Almost made it, before I lost all power :(

    [​IMG]

    Looks like troubleshooting time. Thinking main fuse, maybe short in the wiring. Bike has been pretty troublefree for the 12,000 miles. Wish me luck!
  12. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    3,730
    Location:
    Garden City, Michigan
    Good luck, I'm sure it will be something simple.
    Be sure to let us know what you find.
  13. DirtyDog

    DirtyDog Lust for dust.

    Joined:
    Apr 27, 2007
    Oddometer:
    8,292
    Location:
    Tulsa... it's OK
    Any reason this shouldn't be mounted 1) horizontally or 2) lower than the shock body?

    Just curious, because I don't technically know how it works. Extra gas volume, or does it have oil and seals inside?
  14. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    3,730
    Location:
    Garden City, Michigan
    It can be mounted in any position.
    It does have a floating piston in it separating the nitrogen from the oil.
    Now, the shock will get completely filled with oil along with the hose and approximately 1/3rd of the reservoir.
    The other 2/3 rds of the reservoir gets the nitrogen charge.
    This will probably double my oil capacity and add compression adjustment.
  15. RandoCommando

    RandoCommando Wannabe

    Joined:
    Oct 12, 2011
    Oddometer:
    1,498
    Location:
    Philthadelphia, Pennsylvania
    The 2008 and newer KLRs had an issue with the wiring harness rubbing in certain spots.
    Did you have the recall done for the armoring?
  16. Scott_PDX

    Scott_PDX Leisure Engineer

    Joined:
    Oct 18, 2010
    Oddometer:
    3,867
    Location:
    Portland...the newer one on the left side.
    2009 KLR, had the "recall" done on this model. But there were a few areas that they still didn't get. One area said the front fairing, so took that off and found a tiny little cut on one of the wires. It was being rubbed on the soft metal hold down. That little wire kept shorting the main fuse as soon as it got power. Taped it up good, put the fuse back and bike starts fine.

    This spot, looking at the front of the bike sans fairings.
    [​IMG]

    Tiny little rub-through
    [​IMG]

    The culprit - Note the two sparky areas.
    [​IMG]
  17. PNWcrazymike

    PNWcrazymike Adventurer

    Joined:
    Nov 16, 2012
    Oddometer:
    26
    Location:
    Bend, Oregon (in the sunny half of the state)
    Thank you for the photos! I'll take a look at mine now I know what/ where to look for!
  18. Murphy Slaw

    Murphy Slaw Long timer

    Joined:
    Oct 1, 2011
    Oddometer:
    1,710
    Location:
    Southern Illinois
    That's just crazy, man.
  19. Aprilia

    Aprilia Been here awhile

    Joined:
    Sep 15, 2008
    Oddometer:
    783
    Location:
    Flagstaff, AZ
    GenII's have about 6 consistent places that develop rub thru's but I've seen a few others on more than one bike. Strip the bike down and just start going over EVERYTHING. :wink:
  20. KamikazeKLR

    KamikazeKLR Shorty on the 650

    Joined:
    May 1, 2012
    Oddometer:
    685
    Location:
    Winnipeg, Manitoba
    Hey everyone, I haven't posted on this thread in a while but I'm going from Winnipeg to St. John's, Newfoundland on the old '02 in may. What is a list of things I should do to the bike before leaving? Besides doing the doo. I'm planning to do that already.