Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Kawasaki

Kawasaki Kawasaki Tech Forum - For Questions specific and of interest to Kawasaki riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 4 Sep 2003
Bal Bal is offline
Registered Users
New on the HUBB
 
Join Date: Sep 2003
Location: Baden, CH
Posts: 14
UK Doohickey...

Hi folks,
I have recently acquired a 1985 KLR600. just to get to know it better, I have decided to check out the infamous doohickey and replace it with an aftermarket item. Is there anyone here who has done this procedure in the UK who is willing to lend/sell me the rotor puller bolt & wrench.

Also, if anyone has any stuff for sale like a large tank, luggage, sump/radiator guards - please let me know and we may be able to do a deal.

Kind regards,

Bal.
Reply With Quote
  #2  
Old 18 Nov 2003
Registered Users
New on the HUBB
 
Join Date: Aug 2002
Location: chicago, IL, USA
Posts: 8
in case you manage to get access to an impact wrench, you do not need the special wrench. That's what they do at the dealership.
Reply With Quote
  #3  
Old 24 Nov 2003
Bol Bol is offline
Registered Users
New on the HUBB
 
Join Date: Nov 2003
Location: Midlands UK
Posts: 7
Bal,
Whereabouts are you in the uk?
Reply With Quote
  #4  
Old 24 Nov 2003
Bal Bal is offline
Registered Users
New on the HUBB
 
Join Date: Sep 2003
Location: Baden, CH
Posts: 14
Bol,
Just south of Leicester.
regards,
Bal
Reply With Quote
  #5  
Old 13 Dec 2003
Bol Bol is offline
Registered Users
New on the HUBB
 
Join Date: Nov 2003
Location: Midlands UK
Posts: 7
Bal,
I may be able to get them to leicester for you to borrow, but will need a cash deposit for them.
Bol

[This message has been edited by Bol (edited 13 December 2003).]
Reply With Quote
  #6  
Old 19 Dec 2003
Bal Bal is offline
Registered Users
New on the HUBB
 
Join Date: Sep 2003
Location: Baden, CH
Posts: 14
Bol,
Cheers. I would be willing to collect or pay for any P&P. Deposit is no problem. Drop us a line. my email is either the one above (work) or bschazmann@hotmail.com
The hotmail one is the one that I will have access to in the next 2 weeks.
All the best,
Bal.
Reply With Quote
  #7  
Old 29 Jul 2006
Registered Users
HUBB regular
 
Join Date: Oct 2005
Location: London, UK
Posts: 63
I know this was posted a while ago, but I'm needing to change the doohickey on my KLR next Saturday and forgot about the requirement for that 'special' tool. Any chance you still have it for hire?
Thanks.
Michelle.
Reply With Quote
  #8  
Old 14 Sep 2006
Registered Users
Veteran HUBBer
 
Join Date: Apr 2003
Location: Cape Town, South Africa
Posts: 305
doohickey - di - doo

Now and forever:

To get the flywheel off a KLR you need to see a good hardware shop specializing in bolts & nuts:
Get a bolt of the dimension M22x1.5 with a thread lerngth of approx 50mm and a hex head.
Next you take the generator covers off and push the bike to the next truck workshop. With the M22x1.5 bolt and the workshop's pneumatic impact wrench the flywheel is off in a few seconds. Note: This flywheel puller works on a wealth of jap bikes as the M 22x1.5 puller thread is some kind of japanese standard.
Perfectionists might file or lathe cut the end of the bolt rectangular to its axis.
The bolt is cheap and usually comes in high tensile steel (12.9) and therefore to prefer to a selfmade flywheel puller. My selfmade puller gave up on a very tight sitting KLR flywheel two weeks ago after 20 years of reliable service on various jap bikes :-/
If you can't get hold of a pneumatic impact wrench you will have to make a flywheel holder:
Take a good quality 36mm open box (one forked end one ringed end) spanner (like Stahlwille Alloy series)
Take a acetylen oxytorch and after clamping forked end in vice make red hot just above and bend into a Z shape to get forked end to sit on flywheel, shaft to curve around flywheel and ringed end to rest under or on top of footpeg. You will have to give the spanner a shape to make the ring come into plane with the fork otherwise the fork will slip off the flywheel when under load. This tool is extremely helpful for torquing the flywheel during assembly, bit reluctant to forge it on with impact wrench:-)

Don't use cheap shit spanners for the flywheel holder as they will break and hurt you. (Esp. after heating and bending them).
Allow the spanner to cool down naturally after bending. NO WATER!!!
Don't use spanner with two forked sides. The flywheel holder sometimes does slip. It hurts!

The flywheel often sits extremely fast. If no impact wrench is around make sure you have people holding the bike and pipes to extend spanner on flywheel puller to stand on top of:-)

Have fun!
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


 
 


HU DVD Summer Special!

Now that summer is here, get On the Road! Take 30% off the Achievable Dream - On the Road! 2-DVD set until August 31 only. Get On the Road! Learn the tips to staying healthy, happy and secure on your motorcycle adventure!

Our veteran travellers share their tips (and great stories) for staying healthy, happy and secure on your motorcycle adventure.

"A fantastic, informative and inspirational DVD."

"It's brilliant - thank you very much!"

Check it out at the HU Store! Remember to use Coupon Code 'ONTHEROAD' on your order when you checkout.


Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!


What turns you on to motorcycle travel?


Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!


New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.


Books & DVDs

amazon

All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.


Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!




All times are GMT +1. The time now is 02:33.