KLR650 Only Thread......

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

  1. newcastleadam

    newcastleadam Artful Tagger

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    Was able to pick the dust seal out, then nicked the oil seal enough to allow the air pressure to pop it. :evil
  2. DirtyDog

    DirtyDog Omnia mea mecum porto

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    Yes, mine was black like that.
  3. DirtyDog

    DirtyDog Omnia mea mecum porto

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    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.
  4. ADW

    ADW 'tard bike restos

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    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.
  5. newcastleadam

    newcastleadam Artful Tagger

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    Good tip. I did wrap the seal in a rag, mama didn't raise no fool :D
  6. bomber60015

    bomber60015 tikkun olam

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

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

    IDRIDR Take me to the River

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  8. GAS GUY

    GAS GUY MILE EATER

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  9. Scott_PDX

    Scott_PDX Leisure Engineer

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    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!
  10. GAS GUY

    GAS GUY MILE EATER

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    Good luck, I'm sure it will be something simple.
    Be sure to let us know what you find.
  11. DirtyDog

    DirtyDog Omnia mea mecum porto

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    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?
  12. GAS GUY

    GAS GUY MILE EATER

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    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.
  13. RandoCommando

    RandoCommando Wannabe

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    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?
  14. Scott_PDX

    Scott_PDX Leisure Engineer

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    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]
  15. PNWcrazymike

    PNWcrazymike 3 √ 74

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    Thank you for the photos! I'll take a look at mine now I know what/ where to look for!
  16. Murphy Slaw

    Murphy Slaw Long timer

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    That's just crazy, man.
  17. Aprilia

    Aprilia Long timer

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    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:
  18. KamikazeKLR

    KamikazeKLR Shorty on the 650

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    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.
  19. DirtyDog

    DirtyDog Omnia mea mecum porto

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    Cool, man. Is this added on to the stocker or to an aftermarket shock? Seems like this concept could be used on the stocker at the schrader valve.
  20. GAS GUY

    GAS GUY MILE EATER

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    Added on to the stock shock.