My 685 kit installation - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 64 Old 02-06-2011, 07:17 PM Thread Starter
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My 685 kit installation

I'm at just shy of 20K miles and am going to put a 685 kit in the beast. I'll chronicle it here.

This afternoon I tore the thing down; it was pretty straightforward. There are a couple of hidden fasteners that keep the head from coming off, the most insidious being a small bolt down in the cam chain galley. Referring to the manual keeps the frustration to a minimum.

I decided to measure the bore to see how tapered and out-of-round it was.

I measured it in the for and aft diameter and 90 degrees to that, taking a measurement at the top, middle, and bottom of the cylinder. I set the top for and aft measurement as my zero point.

_____________For/Aft Axis____Right/Left Axis

Top__________ 0.0000"_______ -0.0007"

Middle________+0.0005_______-0.0010"

Bottom________+0.0008_______-0.0009"

Thus, the max out-of-round is 0.0017", at the bottom of the cylinder.

The max taper is along the For and Aft Axis at 0.0008".

There was no scuffing or scoring on either the piston or the cylinder. The piston showed a very slight bit of wear on the skirt, while the cylinder is smooth - no crosshatch left. Pretty much what you'd expect to see, I think. The ring gaps were properly oriented.

The head and cylinder are packaged up and ready to go off to M-Tech up in Bend, Oregon tomorrow. they will bore the cylinder, port the head, install big valves, hopefully set the valve clearance, and ship it back to me in abut 10 days.


T

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“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

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Last edited by Tom Schmitz; 08-28-2012 at 03:26 PM.
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post #2 of 64 Old 02-06-2011, 07:39 PM
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Cool! I'm no machinist or anything, so I'm not sure but 0.0017 isn't that bad for out of round is it? Was your bike an oil burner? I eventually hope to do mine as well, it's not really using oil but I rode a 685 of a friends and I liked the extra "kick"

Cheers,
Stew

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post #3 of 64 Old 02-06-2011, 09:37 PM
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Quote:
Originally Posted by 650Stew View Post
Cool! I'm no machinist or anything, so I'm not sure but 0.0017 isn't that bad for out of round is it? Was your bike an oil burner? I eventually hope to do mine as well, it's not really using oil but I rode a 685 of a friends and I liked the extra "kick"

Cheers,
Stew

I don't know either, wonder what a new or non oil burner measures?

Tom did the rings look like they were making contact all the way around? The rings will expand some as they go up and down the cylinder, 1 thousandth seems reasonable. The rings will rotate there's no post in the grooves to stop them like on a 2 stroke.

I remember you saying that you burned a lot of oil on your Death Valley trip. Was the head gunked up? Top of the piston? Did you notice a blue cloud following you?

Another question, do you have the thermobob installed?

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9

Last edited by Spec; 02-06-2011 at 09:47 PM.
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post #4 of 64 Old 02-06-2011, 10:07 PM Thread Starter
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Spec and 650Stew -

I thought the cylinder was in pretty good shape. A couple of thousands isn't that much for out of round, and less than a thousandth of taper is nil.

The rings were shiny all around, so contact was there.

The head and piston were good and gunked up. I have pictures that I will try to post up (I need to set up another flickr account; too cheap to spring for a pro account).

I've been told that she smokes a bit by folks following me... Stew: yup, she's a real oil burner.

T-Bob was installed some time ago. Don't remember the exact mileage.

T

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #5 of 64 Old 02-06-2011, 10:26 PM
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Ah, so it was a burner... Perhaps I've just been lucky with mine so far. I only have 9000km's on mine though, so perhaps consumption will go up yet. I had read accounts of the ring grooves all being lined up, but your ring end gaps being staggered kind of discounts that one. Sure would be nice to find out the "silver bullet" that causes all that oil to blow through. I'll be following this thread with great interest, I think the 685 is a great upgrade, the power difference is definitely noticeable, especially climbing from a stocker onto a 685. Thank you for taking us along with your upgrade .

Cheers,
Stew

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post #6 of 64 Old 02-06-2011, 11:03 PM Thread Starter
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The bore:



The gunk:


Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 02-06-2011 at 11:07 PM.
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post #7 of 64 Old 02-06-2011, 11:20 PM
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Thanks for taking us along on this adventure, Tom. So many things can contribute to oil consumption, and a combination of a couple of them would be impossible to pin point I would think. Valve seals are bigger culprits on today's engines more often than rings. I have no evidence that this is an issue with the KLR. Break in procedures, operating temperatures, load weight, wind, operator riding habits, on and on and on...... Ring flutter would be hard to confirm outside of a laboratory atmosphere, and even then to be able to replicate the oil usage amount with consistency would be difficult.....

And if the cylinder is the issue [distortion being a top speculation concerning oil consumption], how is the cylinder improved by reaming it out, creating an even thinner cylinder wall.....although it seems to work.

"Head work" is a black art in my book. Larger valves serve a purpose. As far as the porting, how much is taken off where is a mystery to me. I can't pin anyone down to specifics as to where they machine, and how they determine how much to machine off. Polishing makes sense to me. I have no proof it enhances performance, but it makes sense that smooth surfaces would enhance flow. Hopefully I will learn as I follow along here. I have every confidence that this project will be done right, and all outcomes will be reported objectively. My bike, the "'Little Valdez", is pushing out about one and a half gallons of oil per 1200 miles. I need a solution and will be watching carefully.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
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post #8 of 64 Old 02-07-2011, 01:12 AM
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So, next trip we're trading bikes, right?

Soon, we ride. (congrats on the 685 brother...looking forward to hearing about the change)




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

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post #9 of 64 Old 02-07-2011, 09:18 AM Thread Starter
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vatrader-

I'm doing the head work/valves because it's off and because I can - no real reason other than that.

Pictures were taken of the intake and exhaust ports; perhaps we'll be able to see the difference. My understanding is that there really isn't much room for porting on the KLR head, so it will probably be a bit of clean up of the casting more than anything else.

And on the cause of the oil consumption, I gotta tell ya I was hoping to find a distorted cylinder. The only thing I can figure is that, with the cylinder in that condition and with only 20K on the engine, the oil has to be going past the rings.

I'm with ya on the boring out thing - it's an 80-over bore! Yikes!

Sure glad the KLR is not rare and not expensive....

Tom

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #10 of 64 Old 02-07-2011, 09:20 AM Thread Starter
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Quote:
Originally Posted by Lockjaw View Post
So, next trip we're trading bikes, right?

Soon, we ride. (congrats on the 685 brother...looking forward to hearing about the change)
You take the KLR, I'll take the 450....

T

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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