07-23-2009.....Found the front brake problem

Here's a shot of the crap I found in the caliper. Fortunately, the bore was not scored and once I get my new seals and pistons, it should be good as new. I received the master cylinder parts today and assembled the cylinder and installed it. Once I get the caliper parts and new pads, it should only take a couple of hours to finish it and be riding again.

07-16-2009.....Down she goes!!

My son Erik was riding the bike today and suddenly went down. The front caliper had locked up. A scuffed knee and a bent shifter, but all in all came out OK. I'm still not sure what caused the lockup, but the whole braking system is now going to be rebuilt/replaced. Upon inspection, the caliper pistons are seized. Additionally, the PO had installed a different master cylinder. Fortunately he passed along the original with the bike and I'll be rebuilding it along with the caliper. Parts are already ordered. I don't want to sacrifice a wonderful summer here in Colorado, if I can help it, and certainly don't want a repeat of this type of system failure. With the stock M/C, I regain a right side mirror for road riding. Definitely a plus.

07-07-2009....Choke lever relocation

I used an Eagle Mike KLR mirror/choke relocation adaptor ($16.95), a Motion Pro KLR choke cable for a 2000 KLR $15.35) and a factory choke thumb lever ($11.70) - also for a 2000 KLR from Bike Bandit. This worked perfectly and got rid of the right side push-pull ornery choke knob (dumb design). Hold the lever to the left for your start, pull up the rpm's a little and release the choke lever. Spring tension slowly disengages the choke on it's own.... Sweet!

06-29-2009....Manual Tensioner installed

Finished the manual cam chain tensioner today and what a difference. Combined with the carb work, this thing smokes. Everything is improved. It quacks in mid-range. Idles better. All around smoother.

06-28-2009....Carb done.

Rebuilt the carb today using a 135 main, 38 pilot and an "R" needle and an "EZ Just" idle mixture needle. I used the factory numbers for my elevation, and combined with the "R" needle, it worked great. It cleaned up nice and does it scream! Mid-range is a whole new world! Before the rebuild, it had a stutter at any constant throttle position. Really irritating. No More! This was definitely worth the effort.

The only other fuel related upgrade will be a KLR choke cable and lever relocated to the clutch pivot. Parts on order. It will be good to get rid of the "push me, pull me" knob on the right.

From here we do the manual cam chain tensioner and then on to electrical. The bike has been, well.... neglected in terms of electrics. Nothing that can't be fixed, though, and it will be, soon.

06/25/2009....Tires Done

Mounted the Metzeler Saharas today. Took the bike out and they are fine, exactly as I figured they would be. A little pricey, but the good stuff usually is.

I also received my carb parts today and am ready to tear down the CVK40 and get it running correctly. I got an adjustable "R" needle kit (better mid-range response, $22.56, includes stainless bowl screw kit, free. Woo Hoo!!), several different size mains ($2.50 ea.) and a smaller pilot tube ($5.00) from Schnitz Racing (www.schnitzracing.com. 800.837.9730) I also got an "EZ Just" adjustable idle mixture needle from Harley-Performance.com (www.harley-performance.com) for $16.95. About half the price compared to more popular sources.

Plan is to start with the factory high altitude settings: 135 main, 38 pilot, plus the"R" needle and go from there.

06/23/2009....New Renthal Bars

Today I installed the Renthal bars I had been saving for about 12 years. The original bars were pretty beat up. These bars are a "trials' pattern with less pullback. They more closely fit the natural angle of my wrists and as a result are a lot more comfortable than the originals. They are 4 inches wider for more leverage and also get weight farther forward and should contribute to the bike's stability in the dirt.