2008 KAWASAKI KLR650 Engine And Engine Cooling Problems

THE STARTER IDLER GEAR SHAFT HOLE/SLEEVE IS BORE/MILLED TO DEEP ON THE OUTSIDE CASING. THE SHAFT MOVES TO THE CASING SIDE AND LOSES CONTACT WITH THE INSIDE BUSHING/SLEEVE, WICH FORMS A GAP AT THE MAIN HOUSING SIDE. THERE IS NOW ENOUGH SPACE FOR THE SPACER WASHER TO FALL INTO THE BOTTOM-END AND CAUSE HUGE/CATASTROPHIC FAILURE. *TR

2008 KAWASAKI KLR 650 STARTER GEAR COVER IS IMPROPERLY BORED ALLOWING SUPPORT SHAFT TO BECOME UNSUPPORTED ON ONE END. THIS COULD CAUSE THRUST WASHERS TO DROP INTO THE ROTATING FLYWHEEL AT SPEED, LOCKING THE MOTOR AND CAUSING LOSS OF CONTROL. OLDER AND NEWER MODELS BOTH HAVE A RIDGE IN THE OUTER ENGINE COVER THAT PREVENTS THE IDLER GEAR SHAFT FROM DRIFTING OUT TOO FAR AND LOOSING SUPPORT IN THE INNER ENGINE COVER. THIS WAS CLEARLY A MACHINING ERROR. I INSERTED A SMALL SPACER IN THE HOLE TO PREVENT THE SHAFT FROM MOVING. *TR

THE SAFETY ISSUE IS ON A 2008 KAWASAKI KLR-650. THE STARTED GEAR IS GRINDING WHEN I TRY TO CRANK THE BIKE. THE DEALER WILL NOT FIX THE ISSUE. THE CAUSE OF THE FAILURE IS A DEEP BORE ON THE SIDE COVER THAT HOLDS THE GEAR. IT IS A MFG ISSUE. MY CONCERN IS WHEN THE GEAR LOCK UP? THERE IS A GOOD CHANCE IT COULD LOCK UP AS I'M RIDING DOWN THE RODE. *TR

THE STARTER GEAR SHAFT CAN MIGRATE OUT IN THE LEFT SIDE ENGINE COVER, LEAVING THE GEAR UNSUPPORTED ON THE INBOARD SIDE AND ALLOWING A WASHER TO MIGRATE LOOSE INTO THE ENGINE--POTENTIALLY CAUSING THE TRANSMISSION TO LOCK UP OR THE TIMING CHAIN TO SKIP TEETH AND CAUSE THE INTAKE OR EXHAUST VALVES TO HIT THE PISTON TOP, BENDING VALVES AND MAKING THE ENGINE INOPERABLE. *TR

COVER SIDE HOLE THAT LOWER STARTER GEAR PIN RIDES IN IS MILLED TOO DEEP AND CAN RESULT IN SEVERE ENGINE DAMAGE. WHILE INSTALLING A BALANCER TENSION SPRING UPGRADE (ANOTHER ISSUE WITH THESE MOTORCYCLES) I FOUND I HAD THIS ISSUE. I HAD TO INSTALL A SPACER TO FIX AND PREVENT THE OTHER SIDE FROM COMING OUT OF ENGINE SIDE HOLE AND CAUSING DAMAGE. *TR

2008 KAWASAKI KLR 650 ENGINE USES AN ABNORMAL AMOUNT OF OIL, LEADING TO ENGINE SEIZURE/FAILURE/COSTLY DAMAGE. *TR