Rebuilding 2008 KLR Part 2

The rebuild of the KLR continues. Or, perhaps I should say, the teardown of the KLR continues. This post will be focusing on the replacing of various bits and bobs that have broken while I was doing the teardown (mostly due to user error).

First up is the fan switch for the radiator, which as you can see in the picture below, got quite mangled when I was trying to just unplug it from the radiator.

Thankfully, the good people over on klrforums had an answer for where to find a replacement. And after purchasing a new one, a pin remover kit, and much consternation trying to figure out how to use the pin-removal tool, I was able to get the old one off without further mangling it, and install the new one.

Next was the rubber grommet on the wire that attached to the starter which disintegrated upon my removing it. Specifically, part #92071-0705. I found a cheap OEM replacement one on ebay replacing it was ’easy as farting’, as they say.

Before (Sorry for the out-of-focus photo):

After:

The last piece that had to be replaced was the nut on the choke plunger. Once again, klrforum.com to the rescue! They reccomended the replacement plastic one from eaglemike.com which had expensive shipping but worked perfectly.

Before

After:

Stay tuned for more, I’ve already broken other parts that have to be replaced! And have made a lot of progress on the tear down!