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KLR Experts - tools needed for splitting cases?

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jbird710

jbird710

Don’t you know about the Bird?
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First Name
Jay
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Birdsong
Anthony is having issues with his KLR 650 stuck in 2nd gear. He pulled the side covers but it appears there is something stuck in he shift linkage inside the case. He asked me to inquire what tools are needed to split the cases? Also, if anyone can spare the tools for a few days or recommend where to get them, that would be appreciated as well. I may have a flywheel puller that would work, but never having worked on much other than Honda dirt bikes, I wouldn't know what size is needed or if it requires something special.
 
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That would definitely work, but the reassembly may be a bit difficult.
 
Flywheel pusher
https://www.denniskirk.com/28815.sk...DsCh3gVwIlEAQYASABEgLsnfD_BwE&ad=154651356211
Case splitter
https://www.rockymountainatvmc.com/p/989/17167/Tusk-Crankcase-Splitter

Impact screwdriver

To go back together

Crank puller

https://www.rockymountainatvmc.com/p/989/17166/Tusk-Crank-Puller-Installer-Tool
2 or 3 torque wrenches

1/4” inlb —-valve train, case bolts,
3/8” ftlb most fasteners
1/2” ftlb transmission nuts, flywheel

You will get opinions saying no such tools needed

But people have opinions that the earth is flat as well so consider that
 
Last edited:
Jay did Anthony find all pieces of the broken spring? Is that what he suspects is stuck inside? No way to free it and extract without pulling the engine and splitting the cases?

_

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SilverBullet said:
Jay did Anthony find all pieces of the broken spring? Is that what he suspects is stuck inside? No way to free it and extract without pulling the engine and splitting the cases?

_

Sent from my SM-G860P using Tapatalk
Click to expand...

He said there is something stuck in the gears/shift drum he can see through a port in the case. He said he was afraid to just try to pull it out for fear of it breaking off. Also said it appears to be some kind of rubber but has no idea exactly what it is or where it could have come from. The oil filtering screen had small chunks of rubber in it when he pulled it out. He looked on a parts fiche trying to find something that looked like it or possibly see where it could have come from, but couldn't find anything. Not knowing anything about KLR's, I asked him if it might be part of a chain slider for the cam chain (don't know if the KLR uses one). He said the bike has about 30k miles on it.
 
E.Marquez said:
Flywheel pusher
https://www.denniskirk.com/28815.sk...DsCh3gVwIlEAQYASABEgLsnfD_BwE&ad=154651356211
Case splitter
https://www.rockymountainatvmc.com/p/989/17167/Tusk-Crankcase-Splitter

Impact screwdriver

To go back together

Crank puller

https://www.rockymountainatvmc.com/p/989/17166/Tusk-Crank-Puller-Installer-Tool
2 or 3 torque wrenches

1/4” inlb —-valve train, case bolts,
3/8” ftlb most fasteners
1/2” ftlb transmission nuts, flywheel

You will get opinions saying no such tools needed

But people have opinions that the earth is flat as well so consider that
Click to expand...

Thanks E. - will pass this on.
 
jbird710 said:
Thanks E. - will pass this on.
Click to expand...

Reality is, people disassemble motors, install some parts, assemble and get it running with a nice 236 piece craftsmen tool kit, 16oz framing hammer and roll of duct tape................ but if no damage is done on disassembly, nor parts damaged during reassembly, and it actually runs more then a few hours as well as it could, as long as it should....its shear luck masquerading as skill and experience.
No different than the drunk driver making it home and then claiming "See, told you you there was nothing to worry about"
 
E.Marquez said:
Reality is, people disassemble motors, install some parts, assemble and get it running with a nice 236 piece craftsmen tool kit, 16oz framing hammer and roll of duct tape................ but if no damage is done on disassembly, nor parts damaged during reassembly, and it actually runs more then a few hours as well as it could, as long as it should....its shear luck masquerading as skill and experience.
No different than the drunk driver making it home and then claiming "See, told you you there was nothing to worry about"
Click to expand...

I hear you. I've done top ends on several bikes and other motor work; but honestly, never split cases. My dad pretty much beat into me to use the right tools for the job (even though he often didn't and I saw the results). I'm sure Anthony has no desire to damage anything during the process.
 
He still needs to split the cases. He borrowed an impact from another member here to pull the clutch basket, but that's as far as he's got.
 
jbird710 said:
He still needs to split the cases. He borrowed an impact from another member here to pull the clutch basket, but that's as far as he's got.
Click to expand...

I know somebody very knowledgable on KLR's and their specific issues. Will text Anthony. Hate to see him do more work on this than needed.

_
 
SilverBullet said:
I know somebody very knowledgable on KLR's and their specific issues. Will text Anthony. Hate to see him do more work on this than needed.

_
Click to expand...

I'm sure he would appreciate it. He said it's been a little too cool to get down on the floor of his garage to work on it. I think he's a little leery of the scope of the project to split the cases and I know I would be too.
 
Jay,

Could it be this?

[ame="https://www.youtube.com/watch?v=eBrnkPR7Jis"]https://www.youtube.com/watch?v=eBrnkPR7Jis[/ame]
 
He's already looked at that spring as several others had mentioned it. Said the one on it was in good shape, but replaced it anyway - made no difference. Per Anthony, there's something bound up in the gears/shifting mechanism inside the cases he can see through some access ports in the case sides.
 
He ended up pulling the engine and taking it to Pasadena Kawasaki. .They fixed it up and, sorry, I don't remember all that was wrong. I want to say a piece of the timing chain slider was wrapped up in either a gear or shifting drum, but not sure. The guy hasn't been to our regular Wednesday night dinner for a while.
 
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