klr 650 anyone use the hot cams?

Discussion in 'Thumpers' started by side-wayz, Mar 26, 2011.

  1. side-wayz

    side-wayz See Ya in the twisties

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    I heard the valves chattering on my klr and figured I needed to re-shim it, when I got it apart, I found that the exhaust camshaft had spun a bearing and ruined the shaft. I'm trying to find parts now and ran across the " Hot Cams" on klr650.com . Has anyone tried these, and what if I don't need the intake camshaft? Looks expensive to buy both, is it worth it?

    Thanks for any info!



    014.jpg
    #1
  2. Skowinski

    Skowinski Bipedal Tetrapod

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    Aren't these plain bearing heads? I don't think there is a bearing shell in the head, which means the head is also probably trashed....
    #2
  3. side-wayz

    side-wayz See Ya in the twisties

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    This is the first time I've taken a klr apart so I'm not sure about that, but the bike was still running great and I just started to hear a chatter in the top end so when I took it apart, this is what I found. I hope it is not any worse than it looks. The camshafts are over 200 bucks each so far! It's cheaper to get the high performance ones, but the intake shaft looks good and I'm pretty sure if I got the Hot Cam for the exhaust, I would also have to get one for the intake.
    #3
  4. side-wayz

    side-wayz See Ya in the twisties

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    You're right. I see what you're talking about now. No bearing, the shaft just rides on the head. It probably is trashed, but I didn't want to go any further until I found a camshaft. Guess I need to dig in the rest of the way and see if I need a head.
    #4
  5. Skowinski

    Skowinski Bipedal Tetrapod

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    Sorry to see your troubles.

    Was that the only one that was scored? I think that kind of damage is usually caused by a lack of oil, like the supply to the head, so more than one journal is usually damaged. You probably want to look into that before you put it back together with new parts.

    I believe I've heard of KLR's having the oil screen behind the clutch cover become clogged, leading to low oil supply to the head, but not 100% sure, just an idea that comes to mind. Could also be the oil pump, how many miles on this beast?
    #5
  6. tagalong

    tagalong Been here awhile

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    The usual culprit on the KLR for a ruined exhaust cam is the oring on the oil crossover tube blown out. Kinda sad that a $1 piece can cost so much to fix. The oring is on the oil tube which snaps into the left cam caps, it usually gets damaged without you knowing it when the cap is removed while doing a valve shim change. You can see the tube in the pic, it's on the far left center of the pic. The oil from the pump is supplied on the intake cam side and flows through this tube to lube the exhaust cam. If the oring on either side leaks, then the oil doesn't make it to the exhaust cam.
    #6
  7. Beezer

    Beezer Long timer

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    Run low on oil. I've fixed a couple like that. You're looking at a new (serviceable) head as well as a cam. You will also want to pull the oil screen (under the clutch side cover) which requires taking the water pump impeller off. The screen will be full of metal. So is the paper filter BTW.

    I saw something somewhere about a guy that re-bushed & machined the damaged cam bore but I can't find it anymore. A bit of a tossup... used head vs, machine work price wise.

    I might have a spare cam... havta look.


    P.S. watch out for the guide bushings, they have a habit of falling out & dropping into the left side.... OK if you are planning on doing the Doo, other wise.... watch out. I Locktite the buggers in, 'cause it's a problem ever time you set the valve lash.
    #7
  8. side-wayz

    side-wayz See Ya in the twisties

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    Thanks for the knowledge guys. The tube does look like it was leaking so I'll be sure to fix that if I rebuild it. Heads definately shot. I think I'm going to try and find a used engine for now but rebuild this later. I was told that the lower end may need rebuilt now. If anyone knows where a wrcked klr is or a used engine is, please let me know. I'll be searching. :baldy
    #8
  9. side-wayz

    side-wayz See Ya in the twisties

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    Definately lack of oil, I'm learning the hard way. Almost 20,000 on it and I have not done maintenance like I should have.
    #9
  10. side-wayz

    side-wayz See Ya in the twisties

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    I was very careful with the bushings, they're all accounted for. The metal was a concern. Will I have to rebuild the lower end because of this or will it last as long as I get the shavings out of the screen and filter? The bike was still running strong, I tore it apart because of the noice in the head. Let me know if you have tthe camshaft and what you want for it. Thanks.
    #10
  11. kjackbrown

    kjackbrown Been here awhile

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    Ugh...looks like I am in the same boat as you!

    I bought a 2006 KLR last week and started to notice that the P.O. didnt really do much of any maint. on this bike. I ordered the parts/tools to do the Doo and tore into it this weekend. I first wanted to check the valve clearances and as soon as I removed the valve cover, I noticed that the two bolts holding the right exhaust cam cap were VERY loose (several threads showing)!!!!! Further inspections showed that this cap (and cam) were gouged...although not quite as badly as yours.

    The Doo and spring on mine were both broken and missing pieces, I have ordeed a new clutch cover gasket so I can take that side apart and check out the oil screen for the missing pieces.

    Like yours, mine ran very well before I opened it up. I'm going to go ahead and get the correct shims to complete the valve adjustment...and put it all back together. I'm hoping that the bike will still run good....until I can fins a god used head and ex. cam somewhere.

    That being said....what years of KLR650's should I be looking at for a donor head for my 2006? Anyone have (or know of) any that they would be willing to sell?
    #11
  12. newcastleadam

    newcastleadam Artful Tagger

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    You'll also be taking off the water pump, so order up a new gasket and seal kit. Here's a good how-to link.

    Probably want to stay within 1996-2007 model years because the cylinder is a bit heavier duty. That way if you want to drop a 685 kit in there it's just a bore-over job, no new cylinder sleeve required.

    They pop up on occasion on eBay, check your local CL, maybe post a wanted ad here on advrider.

    Edit:
    Fill out the location info on your profile, someone might have something close to you.

    Edit edit:
    Made a comment about cylinder sleeves when you were asking about heads, sorry about that. You will still want to stay 1996 and up. The KLR650 entry in Wikipedia has a quick rundown on model year changes.
    #12
  13. kjackbrown

    kjackbrown Been here awhile

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    Thank you for the heads up on the pump gasket...I'll place my order after lunch!
    #13
  14. newcastleadam

    newcastleadam Artful Tagger

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    Make sure you get the seals as well.

    [​IMG]

    #49063 is the water seal, #92049 is the oil seal. You'll want both. I try to keep an extra set on hand just in case. #670 is an O-ring you can generally re-use.
    #14
  15. CA Stu

    CA Stu Master of air potatofication Super Moderator

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    I don't think that is correct...
    Low on oil is really the usual culprit.

    [​IMG]

    :umph
    #15
  16. side-wayz

    side-wayz See Ya in the twisties

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    I'm waiting for an engine to be shipped to me and I'm gonna do a swap. The engine has been bored out a little and has different valve guides so it doesn't burn oil. Mine was burning oil out the exhaust. !987 to 2007 are supposed to be interchangeable. I couldn't find a good deal on a head for nothin! And you have to make sure you have the same caps from the head. I am going to ship mine down to Fl to Franks cycles and he has a guy who repairs the head and line bores it to fit bushings in for the cams to ride in. Good luck, I'll be doing an engine swap this weekend.
    #16
  17. side-wayz

    side-wayz See Ya in the twisties

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    While I was looking up engine years for my 2000, I was finding 87 to 07...but I am an ameture at this, so you may know something I don't know, but I got a 99 engine for mine now.
    #17
  18. guns_equal_freedom

    guns_equal_freedom Long timer

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    Did you start here after you bought the bike?
    http://www.bigcee.com/klr650faq.html

    Q. I fried my head! What do I do?

    A. If your cam journals are scored or chewed up for whatever reason, Engine Dynamics http://www.enginedynamics.com of Petaluma CA might be able to repair the head. They will resurface the cam and rebuild and finish the journals to match the new cam diameter.
    #18
  19. Beezer

    Beezer Long timer

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    sorry no good exhaust cam in my pile... have an intake through,

    you might try Eagle Mike (the doo guy) sometimes he has a spare
    #19
  20. dannythrottle

    dannythrottle The One

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    I just ran across something similar on my right cam. I called eagle mike and he said he'd be able to machine a new one if the head isn't too far damaged. Idk but the parts are lightly scuffed.

    [​IMG]

    [​IMG]

    I had a Iron Butt ride planned later this month, but it looks like I'll have to take the R6 on this one instead :evil
    #20