Anyone had components rattle loose?

I went on my first offroad ride with my WRR this past weekend and on the second day my front brake went out. I looked down and had brake fluid all over my knee. The hose/tube connected to the master cylinder simply rattled loose and was leaking. After 20 minutes of roadside repair (bleeding the system took a long time) it was working, but it was frustrating that a dualsport had an essential component rattle free on it's first time on the dirt. Anyone else have a similar experience?

Someone had a bad day at the factory?

*Funny, i'll have to think about it. I can't think of anything coming loose right now. I have on my street bike thou.

Never had that happen to me on any of my motorcycles.

I did have the brake hose banjo bolt on the rear caliper of my 2003 Yamaha FZ-1 come loose after a rock was kicked up by the front tire, became airborne, and smacked into it.
I lost rear brake action, but tightening and bleeding returned it to normal. :)

That's unusual. Never heard of a brake line banjo bolt loosening.

I have lost both seat bolts, and noticed the handlebar mount under the triple tree on the left side was loose, which is really wierd as that is a self locking nut.

I lost an aftermarket bolt off my luggage rack, too.

I had the nut that holds down the bracket that the airbox panel cover screws into, but other than that nada.

I've had brake calipers and mufflers a little loose when I checked them.

I've lost many bolts off the KLR. It kind of thumps itself to bits.

My Ducati likes to loose fairing bolts because they thread into a rubber mounted nut so you can't truly tighten them. When that happens while touring in out of the way places like Arco Idaho you just rob a spare metric bolt from the KLR beside you.

Currently my rear sprocket on the WRX has been coming loose. I just replaced the locknuts to see if that helps.

I had my license plate come loose and disappear on our July Motarding in the Kootenays trip.

Banjo bolts are one of the very few items I don't regularly check for tightness. I'm too used to those things on antiques where you need to practice voodoo in order to get them to seal in the first place, so I don't touch them if they're not wet.

Shortly after I bought the bike, I disassembled the entire bike, used anti-sieze and loc-tite, both red and blue on everything and reassemble. Havent had a problem yet...

SpaGuru, that's some dedication! I would hope nothing falls off your bike after all of that work.

I do it to every bike I buy. Even the Gold Wing. Gives me a chance to lube all the pivots correctly and double check everything. The WR is made in about an hour and a half on the assembly line... Takes three hours to put together a Gold Wing. Needless to say, there is countless hours in design and development but they are all streamlined for mass production which can result in the simplest of things to come loose or have some other kind of problem... Right now I have a 1989 Kawasaki KVF400 Prairie 4x4 in a million pieces in the shop for a friend who bought it and wanted it gone over and up to "Todd Speed"...

Cant be too careful, especially something that will go 75 down the highway with my ass on it!

Besides, about the only bike that has parts fall off of it is a Hardly Ableson!

Loctight is fine until you need to take something off. Then you've got gummed up threads which are hard to torque properly, etc...

As we say in the the KLR world:
"Loctight is for amatures. Real KLR riders use zip-ties "

Read the bottle. Blue is easily removed and red must be heated for proper removal. Also, not using half a bottle on a fastner is helpful!

As we say in the WR world:

KLR's are for wanna-be's and WR's are the real deal....

SpaGuru wrote:

...
KLR's are for wanna-be's and WR's are the real deal....

Good one.

Actually there is very little overlap between them. (notice I still have both)
(Oh, but I ride trails on street tires )

Forgot, I also had the 27mm steering head nut come loose. Wierd, it is also a locking nut.

That's a nasty one. Fortunately my WR has been good on that front. The KLR practically needs to be welded for it to stay.

ZED wrote:

The KLR practically needs to be welded for it to stay.

I found this screw under my bike today Where does it come from ? Is it really from my bike ? 2 letters on the head "A K "

I dont think that is off the WR. Is the head metric?

Yes its 10 mm

The bracket that holds the side cover on rattled loose but I didn't lose it as it was still attached to the side cover and the bolt (the one that came loose) that holds it on the subframe couldn't fall out as it hit the airbox.

the side panel bracket has come loose on mine and i have had 3 nuts and bolts for the rear sprocket come up missing put lock nuts on them problem solved

sounds like i should check on the side panel bracket.

ZED wrote:

Loctight is fine until you need to take something off. Then you've got gummed up threads which are hard to torque properly, etc...

As we say in the the KLR world:
"Loctight is for amatures. Real KLR riders use zip-ties "

Well, very few KLR guys know anything about loctite or how to use it and we all know that they are too cheap to spend the five bucks to buy it!


Just kiddin' you ZED. Hell, I ride a DR and a R² so we feel like snobs compaired to the KLR mugs.

rokka wrote:

I found this screw under my bike today Where does it come from ? Is it really from my bike ? 2 letters on the head "A K "

No way it's off the WR; I don't recall every seeing a "screw" on that bike, just bolts.

MeefZah wrote:

rokka wrote:

I found this screw under my bike today Where does it come from ? Is it really from my bike ? 2 letters on the head "A K "

No way it's off the WR; I don't recall every seeing a "screw" on that bike, just bolts.

Thank good

SpaGuru wrote:

Shortly after I bought the bike, I disassembled the entire bike, used anti-sieze and loc-tite, both red and blue on everything and reassemble. Havent had a problem yet...

I understand you train of thought, but I would say about 99% of the stuff I have taken off my WR already had loctite on it and was plenty tight. I haven't had anything rattle loose yet in over 6k miles. I have not disassembled the entire bike like you did, but I have had a majority of it apart at one time or another. Not many things I've found that weren't loctited or had locking nuts on them. I am very pleased with the quality of the build, even if you do say it only takes an hour to assemble at the factory.