Wossner pistons vs oil burning - 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 12 Old 05-08-2013, 08:35 AM Thread Starter
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Wossner pistons vs oil burning

Hi I have recently become the proud owner and rider of a 1990 (ish) Tengai, which for the most part is very enjoyable! however the subject of oil consumtion has raised its quite consideable head! Initial thoughts of smoke on start up led me to replace valve seals with no difference noticed. Then as I read up on the subject a little more I found this forum and the many pages and theories around the piston and rings! Unfortunatley it seems the 685 big bore will not work with the liner on a bike of this age, so the other option is a replacement Wossner piston. Has anybody any experience with these on the 650 engine? Will this help my impressive 1 liter of oil in 200 miles being burned?
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post #2 of 12 Old 05-08-2013, 10:13 AM
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I'm not familiar with the Wossner set up, but Eagle Mike has a very slight overbore kit (+.020") that you might want to take a look at.

It's a 658 kit, with a piston by JE.

T

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post #3 of 12 Old 05-08-2013, 10:16 AM
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Quote:
Originally Posted by Ol dirty bike View Post
Hi I have recently become the proud owner and rider of a 1990 (ish) Tengai, which for the most part is very enjoyable! however the subject of oil consumtion has raised its quite consideable head! Initial thoughts of smoke on start up led me to replace valve seals with no difference noticed. Then as I read up on the subject a little more I found this forum and the many pages and theories around the piston and rings! Unfortunatley it seems the 685 big bore will not work with the liner on a bike of this age, so the other option is a replacement Wossner piston. Has anybody any experience with these on the 650 engine? Will this help my impressive 1 liter of oil in 200 miles being burned?

Welcome to the forum!

My guess is that the oil ring is broken or a very worn cylinder. It's an iron liner so you can bore it oversize.

A good machine shop can probably find something cheaper than the Wossner. Hey it's a KLR afterall!

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; 05-08-2013 at 10:21 AM.
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post #4 of 12 Old 05-08-2013, 10:30 AM
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Why not oversize Kawasaki pistons and corresponding ring sets?

In the bad old days, rebores and installation of oversize pistons and rings were common steps in engine rebuilding.

I think Kawasaki catalogs two oversize replacement piston kits.
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post #5 of 12 Old 05-08-2013, 10:35 AM
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If you use Kawi piston and rings you get the rings they are installing in the new bikes now as all old stock gen I piston and rings have been used up. Do you really want a known problem ring set in your bike after suffering this problem already? The EM kits aren't JE pisrons either unless he has changed piston manufacturers. They are Aeris or however you spell it pistons......it's the Shnitz kits that use JE pistons.
It's a personal choice

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post #6 of 12 Old 05-08-2013, 10:47 AM
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willys -

All of the kits that Mike sells right now use JE pistons. I think it was only the 688 that used Arias.

T

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post #7 of 12 Old 05-08-2013, 10:52 AM
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Originally Posted by willys View Post
Do you really want a known problem ring set in your bike after suffering this problem already?
So, ALL Generation 2 KLR650s have the "known problem ring set," willys?

The problems surfacing with some 2008 models still persist, to this day?

You're CERTAIN? The production years, 2008 through 2013 inclusive, universally involve "problem" rings?

I do not expect an answer, but . . . what is your source of this critical information?

Member-wise, how many Generation 2 KLR650 owners on this forum have experienced the "known problems" of defective design/manufacture/material piston rings?

Last edited by Damocles; 05-08-2013 at 10:58 AM.
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post #8 of 12 Old 05-09-2013, 05:20 AM Thread Starter
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Originally Posted by Damocles View Post
Why not oversize Kawasaki pistons and corresponding ring sets?

In the bad old days, rebores and installation of oversize pistons and rings were common steps in engine rebuilding.

I think Kawasaki catalogs two oversize replacement piston kits.
I do have this option available, I can get 1mm oversize OE piston but when I add the ring cost it will be as much as the Wossner option. Also I'm loathed to replace with OE after reading all the threads on this forum as it seems quite likely a "weak spot". Measuring the bore shows no significant wear so my thoughts are a hone to freshen it up + Wossner piston (which come in 0.01mm) oversize options
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post #9 of 12 Old 05-09-2013, 08:43 AM
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Tom you are correct! I stand corrected.....It looks like he has for some strange reason dropped all kits made with Arris pistons, wonder why? He has all of his kits now with the much superior pistons made by JE. Plus he doesn't offer the 688 kit from what I could find. I wonder why? If they only supposedly had 2 go bad....? But that wasn't the fault of the pistons but from the installation from what they said......but hey that is past history and I shouldn't have brought it up....sorry.

It just makes me wonder though why he has opted to switch to the well known and proven piston company JE which has been supplying the 685 and 705 pistons for years. I can't wait for someone to tell us what the big kit feels like.....I'm sure they are now at the limits of the sleeve and the cooling capabilities of this engine in it's stock form.

All interesting news.....great to see someone going after the power once again.

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post #10 of 12 Old 05-09-2013, 10:34 AM
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willys -

My first thought was that it was probably a business decision, going with one company's products.

But then, perhaps there weren't 'only two' that went bad ;^).

T

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“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

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

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