KLR650 Engine Rebuild Photos and Questions!

Discussion in 'Thumpers' started by rectangular, Jan 8, 2013.

  1. TheAnt

    TheAnt n00b

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    Greetings from South Africa Cape Town...

    This has really been a very good read for me and by reading this I almost have the confidence to open up my baby for some TLC...

    Enjoy your thumper and many a safe miles! :freaky

    PS: Next part is to redo the plastics maybe?
  2. wayne_l

    wayne_l Been here awhile

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    thanks for the build pics and walk thru .Im having issues with chain guide placement on intake side .. do you have a clear pic of how it sits ?

    i had the side guide tucked under the top screw in guide but didnt look right then i tried to have the side guide rest against the top but im too short in the chain like its keeping chain to tight . i cant get em above the cam sprockets .
  3. Beezer

    Beezer Long timer

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    wayne... not sure what you are saying... is the tensioner out? did you take the spring out of the tensioner to reset it?

    and rectangular... your tank has 2 tubes out the butt because its a California tank. they have a carbon canister thing that the "49 state" model doesn't have. looks like yer bodywork is a mix & match... that's OK

    sounds like a success to me
  4. Tsotsie

    Tsotsie Semi-reformed Tsotsi

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    A nice write up- thank you.

    A minor correction; the cam chain tensioner is not hydraulic, but a simple spring and ratchet.
  5. TonezFL

    TonezFL n00b

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    Congrats! Nice thread, great pictures. I'll be using it as a resource to fix an '88.
  6. rectangular

    rectangular Adventurer

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    Awesome! I'm glad that this will be a good resource for people.

    Quick update: Getting close to 900 miles on the rebuild! It's been running extremely smooth and hasn't burned any oil.

    I sent an oil sample in to Blackstone on the last oil change at 500 miles for analysis. I think the results will be good.
  7. jpk1080

    jpk1080 Adventurer

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    Awesome rebuild. I can truly say i learned a ton from reading that so thank you for doing it. I'm curious how much you think you might have spent on the rebuild. My current situation is a little different than yours, but there are some similiarities as well. I have never owned a motorcycle, but I do like tinkering. A lot of the parts, tools, etc that you used I'm unfamiliar with but the pictures helped out a good deal. I found a 2008 KLR on craigslist. It too has a bad motor with 12k miles on it. Apparently it was run out of oil and the ad claims it just needs a new head etc. He claims nothing else is wrong with it. He wants 1300 for it. If I can get him down below 1k for the bike, I'm curious if i would be able to get this thing back together and running for another 1000. I too am worried about the lower half of the motor, not just the head. I know the 08's were notororious for burning through oil. I also wonder if there are any other potential issues with the bike that could cost me later down the road. I would def. want to do the 685 cc kit as I guess there would be no reason not to. It seems a little overwhelming now only b/c I haven't yet got any experience with this. 1000 though for a bike that just needs a top end doesn't seem bad at all though and I do have a hangar where I can work on the bike. Here is the ad and thanks for the help.

    http://asheville.craigslist.org/mcy/3873632417.html
  8. Cliffmeister2000

    Cliffmeister2000 Adventurer

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    There's a 2005 in Franklin on eBay. If you could snag it for under $2,000, it would be road ready now, and well worth the money!
    :clap
  9. jpk1080

    jpk1080 Adventurer

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    Funny I literally just found that. Thanks for the heads up bud. Are you close by?
  10. Cliffmeister2000

    Cliffmeister2000 Adventurer

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    No, I'm in Arizona. Just a frequent visitor to eBay, Craigslist, and other sources of KLR parts. :D
  11. rectangular

    rectangular Adventurer

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    jpk1080: I bought the bike for $800, and spent $1200 on all the parts. That includes misc gaskets, gasket sealant and shipping. My budget was $1,500 originally. I expanded it to $2k for the big bore kit. And my final spreadsheet was cost $2,000.36. Pretty happy I was able to fairly accurately predict all the misc costs that tend to add up on projects like these.

    Update: Getting the bike ready for a nine day ride through the Tetons, Yellowstone and Beartooth pass area. Mechanically, the bike has been superb after the rebuild. I'm really looking forward to this ride. After the trip, I'll most likely be selling it to buy a friends 2008 DR650.
  12. hotrod44

    hotrod44 Adventurer

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    anyone know of any pic's of the hot cam photos and install,tips and yea it's the same as ome/stock pic's.
  13. Stich

    Stich n00b

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    This is the glorious result of the Google search "klr650 engine rebuild" at number one. And what a nice thread it is! I have read most of the posts but need to read the whole thing. But mainly, I wanted to bump what I consider the best contribution to a forum I have seen in a long while.

    Now off to pick up my 1987 KLR 650 in Denver on Tuesday. Blown head gasket there. And, the owner painted the thing flat black. Arrrgh. Well, at least it's not pink. I'm thinking cobalt blue.
  14. Old-n-slo

    Old-n-slo Burnin' fossil fuels!

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    I second that! Got back from a ride from Michigan to Prudhoe Bay and back with my '98 pressurizing the crankcase and blowing all the oil out of the vent into the airbox. Winter project will be a tear-down to try to diagnose the cause. This write-up has made me braver!:D
    JohnD
  15. Beezer

    Beezer Long timer

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    the lands crack between the ring grooves & pieces fall out. that lets combustion gas leak past the rings & they blow oil. the rings never break though. I got a couple in my junk pile. I also pulled one down that had a worn piston. the bike had a cruise control that used manifold vacuum pressure for the actuator & the hose came off & vacuumed the rear wheel straight into the carb going across the Denali highway ha ha.... the bore was worn too big for anything short of the 685. speaking of which... the Gen one piston is now an orphan, the rings for Gen II are slightly different, so if you need rings, you need a piston too. don't bother with a Kawi piston... anybody that is that deep into it should just put up the bucks & 685 it. you will be very happy for just a few bucks more (price of a cylinder bore). if you can afford some head work do that too, if not, at least do a little clean up yourself.

    edit... hmmm pix of head work in this thread already. at least grind off the bit of exhaust stud that sticks down into the post
  16. Jack90210

    Jack90210 mindful

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    This is a good thread. :thumb

    Hats off to those who meticulously detail their work in photos and words so that the rest of us have a breadcrumb trail to follow.
  17. sandwash

    sandwash Long timer

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    Why the change to the DR?
  18. bellacoolarider

    bellacoolarider n00b

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    You should do this for a living my friend!:clap
    I only do basic repairs on my 2013 KLR and was hesitant about trying to do the valves my self. This is a great guide. Thank you.
  19. rectangular

    rectangular Adventurer

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    I wish I could! But, I enjoy it and I'm more than happy to put it out there especially if it's helpful to others.
  20. rectangular

    rectangular Adventurer

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    Sorry for the slow reply :cry

    I switched for a couple of reasons, I wasn't too psyched about the KLRs cooling system. Before I sold it, I had some issues with high engine temperatures on slow moving trails on hot Utah days. The DR650 might still be overheating, but there's no gauge to tell me so. :wink:

    The main reason really is that I'm in love with the simplicity of the DR650. It doesn't get much more straightforward than an air-cooled single cylinder.

    There's also some smaller subjective reasons. I felt that the DR carried it's weight on trails a bit better (I'm by no means a good riderĀ… so, this opinion might be wrong :lol3 )

    I will say that the KLR650 was a hell of a lot more comfortable than the DR650. The stock seat on the DR650 is just horribleĀ…

    It is neat comparing the two. I logged a few thousand miles on the KLR650, and I'm up to over 8,000 miles on the DR650. They're both very capable. In the end though, it really comes down to opinion. It doesn't make the debate any simpler when one considers that they can both be considerably modified to suite ones preferences even more.

    Did I just go off on a tangent? :rofl