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Old 07-20-2013, 04:03 PM   #16
Lappeman OP
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Location: Lappe, ON Coldest, wettest place...well not quite!
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Haven't given up....

I managed to get a used impeller shaft from Excalibur today...thanks guys! Have the covers taken off both sides, as the shaft needs to be hammered lightly from one side of the engine and out the other. I need to order a couple of things, so there's still a chance that this trip may fly yet...not holding my breath though.

New used parts...old impeller and thermo are in photo also in the photo


Old Impeller...looks like it was whacked and bent at one time, which would account for the shaft being cracked for awhile before I bought the bike


Opened up


Broken shaft end
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Old 07-20-2013, 06:21 PM   #17
ZZR_Ron
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Could you drill and tap it for this ride, and put a bolt in? It's been done before.

As I told you before, Dryden is not a very friendly town in general.
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Old 07-20-2013, 07:16 PM   #18
PiffleMaster
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Quote:
Originally Posted by ZZR_Ron View Post
Could you drill and tap it for this ride, and put a bolt in? It's been done before.

As I told you before, Dryden is not a very friendly town in general.
Good point. We have some good machinists in this burb...
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Old 07-20-2013, 07:49 PM   #19
Lappeman OP
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Quote:
Originally Posted by ZZR_Ron View Post
Could you drill and tap it for this ride, and put a bolt in? It's been done before.

As I told you before, Dryden is not a very friendly town in general.
Thought about doing that but it's such a small diameter stud to begin with, just wouldn't sit right with me knowing it was below standard, especially when I would be riding it for 15,000kms Maybe if I was cheap and was selling it and didn't care about the next guy...

No problems with Dryden here...now Thunder Bay...
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Old 07-20-2013, 08:04 PM   #20
ZZR_Ron
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Yea, I can see 15k on a "maybe" shaft could be a bit nerve racking.

Look at the bright side, at least you are mechanically inclined enough to repair it yourself!

As I mentioned yesterday, it's no use taking apart mine to get the shaft...it's a part you want to put in new, and my motor has 44k on it.

Piffle, stop being silly!! (NEXT time, WE WILL HAVE A RUM!!!!!)
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Old 07-22-2013, 05:01 PM   #21
Lappeman OP
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Work progress...

Okay, got back to work on the KLR today. Frank, a self certified KLR Doo guru was over to lend his Doo tools and also to give me a much appreciated hand! First thing we did was check the oil screen, since the case was off and we were there. Pulled it out and it was completely packed with silicone bits and plastic bits It is apparently normal stuff for first cleaning, as the black plastic bits flake off of the balancer chain sliders and the silicone is usually from the factory when the bike is put together...but I'm glad we did check it as it was plugged pretty good.



After that we pulled the flywheel and accessed the other end of the water pump shaft. Now I've read about people taking the balancer weights off on the left side and removing the chain...a nightmare in my mind, why not leave everything attached, then it's all still aligned and there's no problem in getting the timing lined back up when the shaft goes back in. So we removed the shaft clip on the left side and after removing the balancer weight and retaining screw clip on the right, we knocked the shaft thru to the right side with a few bangs on the left side of the shaft. One warning though, when the shaft comes loose, it and the bearing fly across the room fortunately no damage. We slide the new shaft in and made sure the alignment notches all lined up and then seated the bearing back in the right side. Everything went together as planned and after about 4 and a half hours, we were filling the engine with oil and antifreeze! We fired her up and it sounded great...hopefully knock on wood, it all stays that way

The two shafts, new and old (painted one)


Shaft removed - looking at left side


Right side


New shaft in and ready for bearing to be seated


All back together with new impeller bolted on


I also found that one of the cheap 12v plugs had already broken and needs to be replaced. Tomorrow I will take the bike out and put some miles on it and hopefully the next day I'll be back in the saddle and running west again!

I anyone in the Thunder Bay Ontario area needs help with a KLR "Doohickey" change, Frank's the man to see. PM me and I'll put you in touch with him.
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Old 07-22-2013, 05:16 PM   #22
calan818
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Fixed!

Rob, glad you got the KLR back in shape! I was bummed reading about your trip being postponed, especially after your pic of you all geared up to head out west. Hope you are able to get back in the saddle and explore the wild west! We are on day 10 of our east coast trip and having a blast. Today we rode the Cabot Trail and tomorrow is the ferry crossing to Newfoundland!
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Old 07-22-2013, 06:57 PM   #23
Lappeman OP
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Originally Posted by calan818 View Post
Rob, glad you got the KLR back in shape! I was bummed reading about your trip being postponed, especially after your pic of you all geared up to head out west. Hope you are able to get back in the saddle and explore the wild west! We are on day 10 of our east coast trip and having a blast. Today we rode the Cabot Trail and tomorrow is the ferry crossing to Newfoundland!
Play Safe!! Seen some of your great pics...I hope to hit the east coast some year!
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Old 07-22-2013, 07:04 PM   #24
ZZR_Ron
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It's really good to hear that you are back in business Rob! Best of luck on your trip...ride the prairies like the wind on the mighty KLR for the next day and a half, and you'll be all caught up!!
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Old 07-22-2013, 08:20 PM   #25
WhicheverAnyWayCan
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Knew you would get back on your steel horse and try the trip again!
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Old 07-22-2013, 08:55 PM   #26
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Old 07-23-2013, 09:15 AM   #27
PiffleMaster
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Lappeman...

Glad you got sorted out relatively painlessly.
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Old 07-23-2013, 04:42 PM   #28
Lappeman OP
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Location: Lappe, ON Coldest, wettest place...well not quite!
Oddometer: 2,195
Update...

I'm suffering from a sinus infection, so I'll be delaying the trip a couple of more days...also waiting for a windscreen deflector to arrive, should help with the vibration on the top of my helmet...it was quite annoying last Friday. Sorry for all the delays but this trip will happen by the end of this week. I took the bike out for a 130km run today and ran great...just like it did the other test runs before my Day 1 fail

Hope you guys bear with me...Thanks!
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Old 07-23-2013, 05:53 PM   #29
PiffleMaster
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Quote:
Originally Posted by Lappeman View Post
I'm suffering from a sinus infection, so I'll be delaying the trip a couple of more days...also waiting for a windscreen deflector to arrive, should help with the vibration on the top of my helmet...it was quite annoying last Friday. Sorry for all the delays but this trip will happen by the end of this week. I took the bike out for a 130km run today and ran great...just like it did the other test runs before my Day 1 fail

Hope you guys bear with me...Thanks!
No worries, I'm experiencing delays of my own.
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Old 07-25-2013, 12:32 AM   #30
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Quote:
Originally Posted by Lappeman View Post
I'm suffering from a sinus infection, so I'll be delaying the trip a couple of more days...also waiting for a windscreen deflector to arrive, should help with the vibration on the top of my helmet...it was quite annoying last Friday. Sorry for all the delays but this trip will happen by the end of this week. I took the bike out for a 130km run today and ran great...just like it did the other test runs before my Day 1 fail

Hope you guys bear with me...Thanks!
I also have the sinus infection from hell.
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