It was a shame you had to go through all that, but wow did it work out for you!

Inadvertently you probably became "one of" the most mechanically knowledgeable people on this forum regard the klx.

Props to you

 

dan, there was little doubt that you'd get it all together and going. You're very thorough. Now, come on down to Utah this spring and put all that work to good use.

 

Likes to thump, the hard part for me is remembering some of this stuff a year from now. Horrible memory. I took a lot of pics though.
TNC I usually have Murphy, and little doubt, helping when I work on things. I went at this project blissfully ignorant of a potentially negative outcome.
Family vaca to Fla. this year and numerous "local" rides will eat up most of my time/$. One of these days I'm going to surprise you though.

 

Yeah, yeah, sure you will. Remember, I'm already near rest home material as it is.

 

I'll tell you: If had Jake and Elwood at the bench with me...............

 

....you could do anything.

The old "were on a mission from god" thing....
Probably my favorite movie of all time.

 

Last night, I pulled the left side case cover for inspection and didn't find any issues. Here are some poor quality photos.



Besides the exterior bolts, remove these two on the bottom found under the starter gear cover.



Remove the left case cover. It should slip off with some resistance from the starter o-ring.

This is the gear to inspect. Looks good as do the case and cover bushings.

 

Glad everything looks good in there Scott. Good to see that you can pull the Idler gear out without pulling the flywheel, I didn't think that would work. Rock on,,,in that heated shop.
Dan

 

Dan,
Thank you for your guidance on this project. After you said you were surprised I could pull the idler gear without removing the flywheel, I got a little worried and looked at it all again but couldn't find any observed wear. Buttoned the left side back together last night.

For anyone else doing this, be sure to not lose the thin washers / shims on the idler and starter gears.


Remaining major items on my to-do list for the KLX
- Coolant flush
- Manual radiator fan switch
- TM36-68 carb
- Flush brake fluids
- Service front wheel bearings
- Install vapor computer speedo sensor
- Replace seat foam and cover (have medium firmness to replace soft foam and new cover, all GutsRacing).

And if I get to it, improve the dash.

 

Reviving an old thread, because I am experiencing the same detonation issues. I agree with Dan on this theory of the piston going backwards. No broken cases, but I did find the center case bushing warn & the gear shaft galled.
So my main question is for solutions to the detonation. It's mainly when the bike is restarted after turning off or stalling. Letting it sit a couple minutes, and it seems to be ok.
I am running a bit leaner than Dan's specs, and usually run 87 gas.
I experimented a bit, and revved the bike mildly a few times, before shutting the bike off. Seemed to cure it.
Is revving cooling the combustion chamber?
Try Higher octane gas?
Colder plug?
thanks