Technical Insights
by Elden Carl
Copyright © 2006 Top Gun Motorcycles. All rights reserved.  Distribution or publication of this document (electronic or otherwise)
is prohibited without the express written consent of the author. For more information or to request permission to publish this
document, please see our
contact page. For information on our pledge to maintain your privacy click here. To learn more about
your friends at Top Gun Motorcycles, read about us
here.
06/01/13

Mis
-drilled Shaft Hole

The Skipper recently gave me a print out concerning a factory machining error in the
inner left cover of some “E” Model KLRs (2008 -2009).

For a compulsive the fix would be to carefully measure the depth of the hole to
determine the exact length of the error followed by having an aluminum plug with a
slight interference fit machined.  Now heat the cover to 180 degrees and cool the plug
in a freezer.  Once driven into place using a plastic mallet and the shaft for a special
tool, you can forget you ever had a problem.

By the way, the problems with using a ball bearing are two-fold:
  1. The difficulty getting the correct length and diameter at the same time.
  2. The possibility of having the sphere roll out of the hole and bounce into a
    troublesome location when the cover is later removed for service purposes.

A piece of neoprene hose should work as long as it is resistant to possible deterioration
caused by exposure to a heat and oil environment.

Neoprene fuel line comes in a variety of diameters and is tough stuff.   Additionally it
will compress if you the make it a little too long.  On the other hand a metal plug that is
too long can at a minimum cause an oil leak.

A better idea than all of the above is to get Kawasaki to repair or replace your parts.  
After all, it is a factory defect and not a broken or worn out part that is normally covered
under warranty.  Good Luck

What's NEW!
Top Gun Motorcycles