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Old 12-27-2017, 09:25 PM   #1
jbird710
 
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KLR Experts - tools needed for splitting cases?

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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Old 12-28-2017, 05:03 AM   #2
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Re: KLR Experts - tools needed for splitting cases?

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Old 12-28-2017, 01:36 PM   #3
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Re: KLR Experts - tools needed for splitting cases?

That would definitely work, but the reassembly may be a bit difficult.
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Old 12-28-2017, 06:34 PM   #4
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KLR Experts - tools needed for splitting cases?

Flywheel pusher
https://www.denniskirk.com/28815.sku...d=154651356211
Case splitter
https://www.rockymountainatvmc.com/p...kcase-Splitter

Impact screwdriver

To go back together

Crank puller

https://www.rockymountainatvmc.com/p...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
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Last edited by E.Marquez; 12-28-2017 at 06:41 PM.
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Old 12-28-2017, 07:56 PM   #5
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Re: KLR Experts - tools needed for splitting cases?

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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Old 12-28-2017, 10:31 PM   #6
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Re: KLR Experts - tools needed for splitting cases?

Quote:
Originally Posted by SilverBullet View Post
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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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.
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Old 12-28-2017, 11:32 PM   #7
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Re: KLR Experts - tools needed for splitting cases?

Quote:
Originally Posted by E.Marquez View Post
Flywheel pusher
https://www.denniskirk.com/28815.sku...d=154651356211
Case splitter
https://www.rockymountainatvmc.com/p...kcase-Splitter

Impact screwdriver

To go back together

Crank puller

https://www.rockymountainatvmc.com/p...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
Thanks E. - will pass this on.
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Old 12-29-2017, 12:12 AM   #8
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Re: KLR Experts - tools needed for splitting cases?

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Originally Posted by jbird710 View Post
Thanks E. - will pass this on.
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"
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Old 12-29-2017, 09:56 AM   #9
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Re: KLR Experts - tools needed for splitting cases?

Quote:
Originally Posted by E.Marquez View Post
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"
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.
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Old 01-23-2018, 11:58 AM   #10
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Re: KLR Experts - tools needed for splitting cases?

Jay did you and Tony get his bike sorted out yet?
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Old 01-23-2018, 03:07 PM   #11
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Re: KLR Experts - tools needed for splitting cases?

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.
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Old 01-24-2018, 12:25 PM   #12
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Re: KLR Experts - tools needed for splitting cases?

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Originally Posted by jbird710 View Post
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.
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.

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Old 01-25-2018, 01:12 AM   #13
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Re: KLR Experts - tools needed for splitting cases?

Quote:
Originally Posted by SilverBullet View Post
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.

_
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.
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Old 01-28-2018, 10:41 PM   #14
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Re: KLR Experts - tools needed for splitting cases?

Jay,

Could it be this?

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Old 01-29-2018, 01:55 PM   #15
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Re: KLR Experts - tools needed for splitting cases?

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.
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