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View Full Version : About to start putting the KLR back together

G-Rex
10-29-2010, 09:30 PM
Yes, I have a thing with taking bikes apart. LOL

I've finally finished all of the maintenance related work I wanted to do. I did find a few things that made me glad I took the bike apart to go over it in great detail.

1) One wire chafed through under the seat
2) Two o-rings and one collar missing from the upper shock mount
3) Two seized swingarm bearings and one that was missing rollers.

Tomorrow, I'll begin reassembly. In preparation for Prudhoe Bay, I've added a 685cc big bore kit, 280w stator, Happy Trails Teton panniers, extra 12v plugs, digital voltage gauge, and a 6.6 gallon fuel tank.

I hope to be riding it Sunday afternoon. :D
derf
10-29-2010, 09:37 PM
How many `miles did it have?
G-Rex
10-29-2010, 09:39 PM
35k and some change Derf. It was in really good shape overall, and the few things I found weren't necessarily unexpected. I'm just a little OCD about going through every system in detail.

Plus, now, when something acts up on the Haul Road, I know the bike inside and out. Of course, since I went to all this trouble, it will work trouble free. :D
Mr Lefty
10-29-2010, 09:43 PM
remember the locktite...

and I've thought about wire tying things like oil plugs...just in case... don't want to loose one (along with my oil) in the middle of nowhere!

I'd like to one day strip the DRZ down... maybe at the 50k mark...
Dave
10-29-2010, 09:48 PM
phew, got your work ahead of you bro ;) too bad you aint closer, i'd bring the beer :lol:
derf
10-29-2010, 10:52 PM
What rear shock is that?
Captain Morgan
10-29-2010, 11:35 PM
Holy cow!! When you said you were going to give the bike a thorough check, you weren't kidding!!
Gas Man
10-30-2010, 03:41 AM
remember the locktite...

and I've thought about wire tying things like oil plugs...just in case... don't want to loose one (along with my oil) in the middle of nowhere!

I'd like to one day strip the DRZ down... maybe at the 50k mark...
Bring it up man.... Looks like an easy job on the lift! ;)
G-Rex
10-30-2010, 09:29 AM
What rear shock is that?

It's a Progressive 420.
Particle Man
10-30-2010, 09:46 AM
Screw it, ride it like that. :lol
Apoc
10-30-2010, 08:54 PM
The good thing is, you have something to do. The bad thing is, when your done, itll still be a KLR :p
G-Rex
10-30-2010, 10:16 PM
The good thing is, you have something to do. The bad thing is, when your done, itll still be a KLR :p

Don't I know it! LOL

I'm not worried about it. I enjoy this stuff, so it's not like a waste of time or anything. I'll have this one finished in a few days and ready to go. Once that's done, I'll probably set it aside and start a similar teardown on the Busa. I'd say she's earned a little TLC after 70,000 miles. :)
Captain Morgan
11-01-2010, 12:29 PM
Don't I know it! LOL

I'm not worried about it. I enjoy this stuff, so it's not like a waste of time or anything. I'll have this one finished in a few days and ready to go. Once that's done, I'll probably set it aside and start a similar teardown on the Busa. I'd say she's earned a little TLC after 70,000 miles. :)

Be sure to follow in Gas Man's steps and post pics of each.
Gas Man
11-01-2010, 09:37 PM
Be sure to follow in Gas Man's steps and post pics of each.
Yes that makes it awesome!
Dave
11-02-2010, 01:36 AM
Yes that makes it awesome!

Only works when you do it though :lol:
derf
11-02-2010, 01:41 AM
I'm pretty sure hes gonna make a video of the assembly process like he did the duc a few months back
Papa_Complex
11-02-2010, 09:05 AM
Damn, but I wish I had a garage. Seeing threads like this makes me jealous. In winter the best that I can do, is a little light fab in the basement :(
G-Rex
11-02-2010, 09:43 PM
Have you used the bearing press yet? For the price, I'm thinking of buying one for myself, assuming parts like motorcycle wheels will fit into it. I imagine it's no good for other bearings/races, like steering stem, swingarm, etc.

You actually have it backwards. It's no good for the wheel bearings, as the wheels are too big to fit. I have a wheel bearing remover set for that.

The press works perfect for the other bearings/races, i.e. swingarm, suspension linkage, and steering stem. :)
G-Rex
11-02-2010, 10:53 PM
I guess I'd have to see the press in action then, because I can't picture any of this. I thought whatever you're pressing would have to fit straight up and down between the legs of the contraption.

Correct. I took some video I think of the press in action. Once I get it posted I'll be sure to link it up.
Particle Man
11-02-2010, 11:03 PM
would have to fit straight up and down between the legs of the contraption.
I knew a girl in college like that...
CasterTroy
11-03-2010, 09:12 AM
Once that's done, I'll probably set it aside and start a similar teardown on the Busa.



:doh::scared:
Mr Lefty
11-03-2010, 10:04 AM
I guess I'd have to see the press in action then, because I can't picture any of this. I thought whatever you're pressing would have to fit straight up and down between the legs of the contraption.

remember he stripped the KLR down to the frame... not hard to get the neck vertical with nothing attached to the frame... but it'd be a PITA to strip the bike down any time you wanted to change the bearings... (then again... don't have to change them THAT often)

I knew a girl in college like that...
:rofl: