Cylinder head from 87-2007 to 2008 - 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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Old 08-01-2013, 07:16 AM Thread Starter
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Cylinder head from 87-2007 to 2008

Can i install the cylinder head assembly from the previous model to my 2008 year? My head was broken due to lack of oil. Now i found a head only from the previous model.
Sorry for my english
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Old 08-01-2013, 10:17 AM
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motophil -

They are all generally interchangeable.

There were some changes in the 1996 model year. I don't think the head was involved, but it might be best to look for a 1996 and newer head.

Tom

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Old 08-01-2013, 11:33 AM Thread Starter
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Tom, are you sure that the head from 96 year and up will suit? The part numbers differ
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Old 08-01-2013, 12:33 PM
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Quite sure. It's been done by people on this forum.

I even think that the pre-'96 will work, but there were cylinder changes in '96, so to be on the safe side I'd stay clear of pre-'96.

We've even had discussion about using a KLR600 head; we think it will work but nobody has definitely tried it.

If you get a complete head from a pre-2008 you will find that the valve timing is slightly different, as the valve timing was changed for the Gen2 bikes. Won't make any difference; it might even run better. If your cams are not toast you could swap them out into the older head.

Do you have a lot of KLRs in Russia?

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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Old 08-01-2013, 03:27 PM
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Yes it works and keep the cams in the old head it's better. Done it many times and none have had any issues what so ever. You can then remove all the crap that Kawi thinks is important for polution specs. The top tube, hose, valve, hose and plug carb hose....job done!

Willys
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Old 08-01-2013, 04:03 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Quite sure. It's been done by people on this forum.


Do you have a lot of KLRs in Russia?

T
I suppose that there are not more than 40 KLR 650 in the whole country )) I am the happiest owner one of it!!
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Old 08-01-2013, 04:13 PM Thread Starter
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Yes it works and keep the cams in the old head it's better. Done it many times and none have had any issues what so ever. You can then remove all the crap that Kawi thinks is important for polution specs. The top tube, hose, valve, hose and plug carb hose....job done!
what crap can I remove from my bike?? Does exist any video or manual for removing it?? I knew that this anti polution crap is really useless thing!!
And what about head from the earlier versions? Can I use a head from the 91 year? I found only a head of this year in the Ebay
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Old 08-01-2013, 06:45 PM
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I can't be 100% sure about the 91 head.....I've always stayed 96 and up. You could search and see if the bare head uses the same part number? I know the lower end is different as in different internal parts.
You can see the pipe that leaves the head, that metal one running up from the spark plug area, anything attached to that can be removed all the way back to the carb. Plug the carb hose where it "T"s, one side goes to the petcock and the other to the pollution valve. Buy the kit to block the metal pipe off at the head or leave the pipe there and block the hose. OR, if you can braze or solder well, take that pipe off, remove the "O" ring and then cut it at 1/2" and then seal it up......even JBWeld would work I would say. Put the rubber "O" ring back on and bolt it back down.
Then it's on the the carb and setting it up to run better. Nothing you have done so far has made it worse....just saying.

Willys
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Old 08-02-2013, 05:41 AM Thread Starter
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Dear Willys
I'll try to cut it down, but after the installation of the new head)). Bare heads even on Gen2 have different part numbers
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Old 08-02-2013, 10:16 AM
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It's the pre 96 and post 96 heads you need to check part numbers for....no? I know the pre 08 and post 08 heads are interchangable.

Willys
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