Tech Day 2010

May 15th was this years tech day held at a local riders (Rick) house in the Spokane Valley. We had about 13 KLRs show up and many of them took a turn in the garage for anything from minor repairs to valve checks and Doohickey replacements. The KLR has pretty much been the same motorcycle since 1987 and has only had one fairly major re-work beginning in 2008. The only real issue that the KLR has is what is called the Balancer Chain Adjuster or in the KLR world a "Doohickey" We had two of our riders crack open the case this year to replace the weak part from Kawasaki with the proven parts from Eagle Mike. When we got the side covers off of Kent's 2005 and removed the flywheel we noticed that the tensioner spring was completely gone. Sadly a common issue with this bike but we now had to try and find the spring before it ended up like this one from my bike.

We ended up completely removing the water pump and clutch side cover and digging the spring out of the oil passage screen where it was lodged in. This is a bit of work but seems to be a common place to find things lost in the engine. Obviously much better to do more work than have a trashed motor. Kent was a busy boy for most of the day as he also lubed his steering head bearings, and put bigger spacers above his fork springs to pre-load the springs more.

Norris made some really cool little kickstand pads that made the footprint of our kickstands a touch larger so when we park the heavy bikes on soft dirt or hot asphalt it spreads the weights out some so the kickstand won't sink and cause the behemoth to fall over. It may just look like a big dirt bike but mine weighs in at 430 pounds. For just a small disc under the kickstand it was a good improvement.

After many more wrenches turned we all decided it was time to go for a little bit of a ride. I mean what good is it to work on on your motorcycle all day and then just park it. We decided to head into Idaho a little ways and fuel up then head towards Mt. Spokane and ride the back roads and see if we could get to the top and drop out on a different road. We cruised all around and came upon some dead ends and typical kelly humps blocking the roads. We stirred up lots of dirt and had a really good time. It is so interesting riding with people of all different skill levels and set-ups on their bikes. Dual sport motorcycles offer a range of tires then can really effect how they perform on and off road. I have fairly aggressive knobbies on mine but it does surprisingly well on the street.

A beautiful day for a ride with good people and looking forward to the next one. These are a great group of guys with a whole bunch on knowledge to pass on to keep these great machines on the move and running for a long time to come.

Ride Safe

-Charlie-

What the heck is a Doohickey?

So this past Saturday a local KLR rider hosted a tech day. My friend Earl Thomas was there with his camera as usual. Check it out here; http://thevampireduck.blogspot.com/2009/05/tech-day.html

I ride a 2002 KLR 650 and for the most part it is one of the most reliable motorcycles available and has pretty much been the same bike from 1987 until 2007. Says a lot for the design and capability of the machine. I read an old Cycle World article recently from I believe 1991 that said the KLR was good at everything but not great at one particular thing. Basically an all around good bike. I really can't disagree as I have challenged myself on the thing and it still leaves me grinning from ear to ear.

The one downfall that the Kawi has is the cam chain tension adjuster. AKA the Doohickey. For some reason Kawasaki used two pieces welded together to make this adjuster and a really weak spring to retain tension. For some reason the doohickey "also referred to as the Doo" tends to break and can cause severe damage to the cam chain and other parts. When this tech day came about I figured it would be a good day to get this done and make sure everything was ok on the bike. Needless to say when I open up the left side of the stator housing and got to the Doo it was broken.

If you look at the picture and see the cam shaped adjuster at the bottom of the case you can see where it is supposed to be a whole piece that goes around the shaft. Not good in my book. We used a magnet and searched and dug all over the case looking for the broken piece but was not able to locate it. The spring for the tensioner had descent tension still but I replaced it and the Doo with a very high quality part from Eagle Mike. (Thanks Mike) Got the bike back together and fired it up to immediately notice a little less noise from the cam chain. Good day all in all and even got a little over a hundred miles logged by days end. Thanks to all who helped!

My broken Doohickey

-Charlie-