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Search: Posts Made By: rectangular
Forum: Thumpers 06-05-2014, 10:48 PM
Replies: 98,654
Views: 18,814,398
Posted By rectangular
I had these exact symptoms out in the middle of...

I had these exact symptoms out in the middle of the Utah desert. Intially my float got stuck open and filled my intake with gas when I dropped the DR in some dunes. It totally flooded the bike and...
Forum: Old's Cool 04-20-2014, 10:36 PM
Replies: 14
Views: 1,803
Posted By rectangular
Do you have a source for that? I know the SR500...

Do you have a source for that? I know the SR500 was made much longer after '81, but everything I found seems to state the XT stopped production in '81. It could be that all the sites I'm referencing...
Forum: Old's Cool 04-20-2014, 09:15 PM
Replies: 14
Views: 1,803
Posted By rectangular
Haha. Yup. That's kinda what I have learned (the...

Haha. Yup. That's kinda what I have learned (the hard way) after the last two times I have changed tires. The youtube how-to videos make it look so easy… :lol2
Forum: Old's Cool 04-17-2014, 11:54 PM
Replies: 14
Views: 1,803
Posted By rectangular
Part 2!

The Yamaha XT 500 was first produced in 1975 and was made until 1981. It shares the same engine with its road relatives, the SR500 and its off-road variant the TT500.

One of the first things that...
Forum: Thumpers 04-14-2014, 11:02 PM
Replies: 98,654
Views: 18,814,398
Posted By rectangular
Awesome! It's for a friend's bike. If you could...

Awesome! It's for a friend's bike. If you could PM me some contact info and/or pics, I'll send it along to him. :clap

For $80, I would rather buy a good functioning carb than have to mess around...
Forum: Thumpers 04-14-2014, 09:52 PM
Replies: 98,654
Views: 18,814,398
Posted By rectangular
Is the price of the Mikuni low enough that it's...

Is the price of the Mikuni low enough that it's not worth fixing up? What's the going rate for a decent used one?
Forum: Old's Cool 04-14-2014, 01:27 PM
Replies: 14
Views: 1,803
Posted By rectangular
Thanks for all the kind words. So far I...

Thanks for all the kind words.

So far I haven't had any kickback or shin-bang when kickstarting… knock on wood! :D

Working on writing up the next installment of this series… trying to touch...
Forum: Thumpers 04-13-2014, 05:05 PM
Replies: 98,654
Views: 18,814,398
Posted By rectangular
Thanks for the clarification on the terminology....

Thanks for the clarification on the terminology. I know that there isn't a choke plate in the airway, but… I just kept calling it a choke anyways :)

I'm not sure if it's a California carburetor or...
Forum: Thumpers 04-13-2014, 04:27 PM
Replies: 98,654
Views: 18,814,398
Posted By rectangular
Calling all Mikuni Carb Experts…

I'm helping a friend of mine with his recently acquired 2000 DR650. It seems we have discovered a fair bit of… interesting bodge jobs (a previous owner must have owned stock in JB Weld). :cry

The...
Forum: Old's Cool 04-10-2014, 10:11 PM
Replies: 14
Views: 1,803
Posted By rectangular
1981 Yamaha XT500 - Project Thread

1981 Yamaha XT500 — Part 1

So far, I've done a terrible job documenting this XT500. I have already had the bike for (more than) a few months.

I purchased the bike on October 26th of last year...
Forum: Thumpers 11-29-2013, 05:51 PM
Replies: 98,654
Views: 18,814,398
Posted By rectangular
Another rattling dr650...

Long time lurker on this thread! I sold my '01 KLR for an '08 DR650 earlier this summer :D

I had a really annoying rattle at certain RPMs on my '08 DR650 develop recently. Tightened the exhaust...
Forum: Thumpers 07-02-2013, 04:18 PM
Replies: 9
Views: 966
Posted By rectangular
Thanks for all the help and suggestions! ...

Thanks for all the help and suggestions!

Yesterday I actually disassembled and cleaned the entire cooling system. I also made sure that it was adequately burped.

I had used some RTV sealant in...
Forum: Thumpers 07-01-2013, 04:43 AM
Replies: 9
Views: 966
Posted By rectangular
KLR650 Running Hot

My 2003 KLR650 has been running much hotter than I would like. It has only really been noticeable in this hot 90° and higher air temps that we've been experiencing in SLC.

It has the procycle...
Forum: Thumpers 06-19-2013, 05:37 PM
Replies: 134
Views: 30,406
Posted By rectangular
jpk1080: I bought the bike for $800, and spent...

jpk1080: I bought the bike for $800, and spent $1200 on all the parts. That includes misc gaskets, gasket sealant and shipping. My budget was $1,500 originally. I expanded it to $2k for the big bore...
Forum: Thumpers 05-19-2013, 10:56 AM
Replies: 134
Views: 30,406
Posted By rectangular
Awesome! I'm glad that this will be a good...

Awesome! I'm glad that this will be a good resource for people.

Quick update: Getting close to 900 miles on the rebuild! It's been running extremely smooth and hasn't burned any oil.

I sent an...
Forum: Thumpers 03-18-2013, 11:16 PM
Replies: 134
Views: 30,406
Posted By rectangular
Talking Final day of the build!

Here we are, at the final build day of the KLR650! Let's get right into it…

Last time I stopped, I just got the head back on. Now, I'll have to finish buttoning that up, and get all the ancillary...
Forum: Thumpers 03-14-2013, 10:17 PM
Replies: 134
Views: 30,406
Posted By rectangular
Talking Finally, back at it!

Hey everyone! I'm finally back at the build. It took almost two months to get a head and some cams, but they arrived last week!

Time to get to work.

I think I have everything together to get...
Forum: Thumpers 02-06-2013, 02:00 PM
Replies: 134
Views: 30,406
Posted By rectangular
Interesting! It still seems like they could have...

Interesting! It still seems like they could have designed a better oil system perhaps. Wet sump seems like a bad idea when it comes to something that could end up running on it's side for brief...
Forum: Thumpers 01-29-2013, 08:57 AM
Replies: 134
Views: 30,406
Posted By rectangular
Glad that everyone agrees the oil pump is...

Glad that everyone agrees the oil pump is good-to-go! Now I'm basically just waiting on gaskets and my refreshed head from Eagle Mike.

I picked up some 10w40 non-synthetic castrol motorcycle oil...
Forum: Thumpers 01-28-2013, 10:13 PM
Replies: 134
Views: 30,406
Posted By rectangular
Oil pump pictures!

I had some spare time tonight to get in and look at the oil pump. It seems to me that it has some signs of wear, but I don't think it's to the point of affecting it's function. The surface feels...
Forum: Thumpers 01-28-2013, 03:18 PM
Replies: 134
Views: 30,406
Posted By rectangular
Nothing is wrong. Beezer mentioned above to put...

Nothing is wrong. Beezer mentioned above to put some punch marks in it. But, I think I'm going to pass on that. Pretty sure I would mess that up. :lol3
Forum: Thumpers 01-28-2013, 03:03 PM
Replies: 134
Views: 30,406
Posted By rectangular
I have some new copper gaskets for the banjo...

I have some new copper gaskets for the banjo bolts.

Sounds like using grease is the way to go so that gaskets can be reused. I like it!

I'm a little paranoid about modifying the woodruff key in...
Forum: Thumpers 01-28-2013, 02:59 PM
Replies: 134
Views: 30,406
Posted By rectangular
I didn't get a jug from Eagle Mike. There's a...

I didn't get a jug from Eagle Mike. There's a pretty awesome local motorcycle machine shop. I had them do all the machine work on the cylinder jug that came with my bike.
Forum: Thumpers 01-28-2013, 12:46 PM
Replies: 134
Views: 30,406
Posted By rectangular
On it! I should underline that step in the Clymer...

On it! I should underline that step in the Clymer manual.

I should have posted build threads like this ages ago. It's good to find out all the stuff I'm doing wrong. :rofl I don't have any actual...
Forum: Thumpers 01-28-2013, 11:20 AM
Replies: 134
Views: 30,406
Posted By rectangular
Yeah. I'm a little slow today. I figured out...

Yeah. I'm a little slow today.

I figured out what was going on once I started looking up pictures of the oil pump. :lol3
Forum: Thumpers 01-28-2013, 10:58 AM
Replies: 134
Views: 30,406
Posted By rectangular
Edit: Nevermind, the oil pump is phillips head. I...

Edit: Nevermind, the oil pump is phillips head. I follow now. :D

Also, I'm probably going to be going in and checking on the oil pump tonight. Anything specific that I should look for once I...
Forum: Thumpers 01-28-2013, 10:06 AM
Replies: 134
Views: 30,406
Posted By rectangular
I don't have a hand impact driver :( ...

I don't have a hand impact driver :(




And it won't cause issues with coolant leaking? Interesting. I might have to give this a shot.

Also, I haven't found a definitive answer if the side...
Forum: Thumpers 01-28-2013, 08:56 AM
Replies: 134
Views: 30,406
Posted By rectangular
Will do. It shouldn't take very long anyways. I'm...

Will do. It shouldn't take very long anyways. I'm getting pretty familiar with both sides under the engine covers.
Forum: Thumpers 01-27-2013, 10:51 PM
Replies: 134
Views: 30,406
Posted By rectangular
I see! Yeah, that does actually seem like a lot...

I see! Yeah, that does actually seem like a lot better way to remove or install. Keeps it nice and even, much less chance of it getting jammed. I'll have to remember that next time I have to install...
Forum: Thumpers 01-27-2013, 09:11 PM
Replies: 134
Views: 30,406
Posted By rectangular
Ahhh... crap. Is this something I can defer...

Ahhh... crap.

Is this something I can defer to after my 20-minute break in? I'll be checking the oil screen at that point too.

(I think I already know the answer to this...)
Forum: Thumpers 01-27-2013, 08:42 PM
Replies: 134
Views: 30,406
Posted By rectangular
I'm not sure I follow. That was the old seal that...

I'm not sure I follow. That was the old seal that we had to drive out. It's the way the Clymer manual specifically described removing the old seal. We ended up punching a hole through the old one...
Forum: Thumpers 01-27-2013, 05:47 PM
Replies: 134
Views: 30,406
Posted By rectangular
Ahh, yup! You're right. I remembered that on the...

Ahh, yup! You're right. I remembered that on the reinstall but forgot about it when I wrote it up. The shortest one is on the far left.
Forum: Thumpers 01-27-2013, 04:00 PM
Replies: 134
Views: 30,406
Posted By rectangular
Day 5 of the Rebuild!

I was not mentally ready to deal with engine case yet, so we moved on to getting the right side of the engine wrapped up.

A little bit of kerosine to clean up the gasket surface.
...
Forum: Thumpers 01-27-2013, 03:59 PM
Replies: 134
Views: 30,406
Posted By rectangular
Continued...

After the cylinder was in, it was time to return to finishing up the doohickey. Consequently, this is where things soon went pear shaped.

The new rotor bolt, ready to be installed.
...
Forum: Thumpers 01-27-2013, 03:58 PM
Replies: 134
Views: 30,406
Posted By rectangular
Moar!

More glamour shots.

http://static.geofcrowl.com/klr4/klr-day4-37.jpg

I kept getting distracted and taking photos of the newly bored cylinder.

http://static.geofcrowl.com/klr4/klr-day4-38.jpg...
Forum: Thumpers 01-27-2013, 03:57 PM
Replies: 134
Views: 30,406
Posted By rectangular
Continued...

Looks like it's a stock doohickey.

http://static.geofcrowl.com/klr4/klr-day4-20.jpg

http://static.geofcrowl.com/klr4/klr-day4-21.jpg

Here's some comparisons between stock and the Eagle Mike...
Forum: Thumpers 01-27-2013, 03:57 PM
Replies: 134
Views: 30,406
Posted By rectangular
Day 5 of the Rebuild!

Continuing on with the build journal.

First order of the day was to start taking care of some cleaning. The rat's nest below the starter was not kosher.

Definitely seems like some oil has been...
Forum: Thumpers 01-27-2013, 10:54 AM
Replies: 134
Views: 30,406
Posted By rectangular
Good news!

I was able to clean up the starter rotor and block block fairly well with the help of a friend. On first glance, the starter rotor looks new and with some mild smoothing out, the block doesn't look...
Forum: Thumpers 01-26-2013, 03:52 PM
Replies: 134
Views: 30,406
Posted By rectangular
Ok. That doesn't sound too bad. I'm still curious...

Ok. That doesn't sound too bad. I'm still curious why Kawasaki spot welded that toothed bit on the back. Seems rather strange.

The cam chain seems fine from a visual inspection. It doesn't seem...
Forum: Thumpers 01-26-2013, 01:05 PM
Replies: 134
Views: 30,406
Posted By rectangular
Well... shat... that's a problem.

Well... ran into a bit of a snag today. I got the cylinder back from the machine shop, got the new piston and cylinder installed. I also got the new doohickey installed as well with the torsion...
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