Taking off the KLR 650 Engine - 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 14 Old 04-13-2014, 02:29 PM Thread Starter
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Taking off the KLR 650 Engine

This is realted to my other post, a problem I am currently working with my KLR, but I feel this question deserves its own thread.

So I would like to ask - Is it possible for me, someone with very limited mechanical knowledge of the KLR - to take the KLR apart to the point where I can take the engine block off so that I can get it welded. WITHOUT taking the engine - just the block itself - so that I can get it to a welder and weld the cracked sump basin.

If its is, can anyone recommend a tutorial, or a useful youtube video?
(I already have the Clymer manual, and I will be searching myself, but I think its good to ask other people - you never know what kind of information is out there that I might not be able to find myself)

Also what kind of tools would I need? Other than the stock tools?

Thank you in advance guys!
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post #2 of 14 Old 04-13-2014, 05:14 PM
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Wow, sounds like a big undertaking to me. I have not mechanical knowledge or tools so I will be interested to read what the experts have to say. Good luck!
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post #3 of 14 Old 04-13-2014, 05:37 PM
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Any pics. of the damage?
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post #4 of 14 Old 04-13-2014, 05:46 PM
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Nope, you have to take the whole engine. Unless your talking about disassembling the whole thing (engine I mean) and taking in just the cases. I guess you could remove the head and jug, but it wouldn't really save you anything or make it any easier for the welder.

I think removing the engine would be doable by someone with limited experience working on motorcycles, especially if you could get a little help from someone that has some wrenching experience . I wouldn't recommend taking the engine apart though unless you know what your doing.

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post #5 of 14 Old 04-13-2014, 06:27 PM Thread Starter
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Originally Posted by 650Stew View Post
Nope, you have to take the whole engine. Unless your talking about disassembling the whole thing (engine I mean) and taking in just the cases. I guess you could remove the head and jug, but it wouldn't really save you anything or make it any easier for the welder.

I think removing the engine would be doable by someone with limited experience working on motorcycles, especially if you could get a little help from someone that has some wrenching experience . I wouldn't recommend taking the engine apart though unless you know what your doing.


Sorry I havent made myself clear. I am talking about taking the engine out, not taking it APART, that I know I dont want to do.

So you I guess I can huh? But you say it would be better someone with wrenching experience help me out. Let me see if I can recruit someone. Also an important question, I have th3 Clymer manual but for 2007 and up years( they didnt have the 2005 series manual in stock when I was buying on Amazon. Is this, 2007 to 2013 manual accurate as per tak8ng the engine block off the 2005 model... I read it and theres 50 different steps, some of which have chapters dedicated to them (lol looks like quite the undertaking for a complete beginner)
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post #6 of 14 Old 04-13-2014, 07:06 PM
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Quote:
Originally Posted by Stirletz View Post
(lol looks like quite the undertaking for a complete beginner)
I think with that comment that you answered your own questions. Myself I would't recommend it. Too many things that can go wrong if you are not familiar with the process. If you can't find someone that can help you leave it to someone who knows.

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post #7 of 14 Old 04-14-2014, 04:01 PM Thread Starter
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Originally Posted by BadDad View Post
Any pics. of the damage?
its in my other thread. The one about the broken sump casing. Its really bad

Quote:
Originally Posted by klr4evr View Post
I think with that comment that you answered your own questions. Myself I would't recommend it. Too many things that can go wrong if you are not familiar with the process. If you can't find someone that can help you leave it to someone who knows.
at the same time, I feel a lot more confident after reading the manual now. I think all i really need is simple confidence in what I am doing and having someone to ask a question or two is much help.

Last edited by Stirletz; 04-14-2014 at 04:05 PM.
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post #8 of 14 Old 04-14-2014, 04:30 PM
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I remember as a 17 yr old kid with no real mechanical ablity (still don't) taking the engine out of my Honda CB350 just to clean up the frame.

Absolutely it is doable, take your time, read the manual and take pictures as you go for re-assembly. Sometimes the hardest part is making sure you have the right washers spacers etc in the right order.

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post #9 of 14 Old 04-14-2014, 04:48 PM
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If you go for it I am sure you will have a lot more knowledge when you are done. I hope it goes well for you.
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post #10 of 14 Old 04-14-2014, 04:48 PM
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Quote:
Originally Posted by Stirletz View Post
This is realted to my other post, a problem I am currently working with my KLR, but I feel this question deserves its own thread.

So I would like to ask - Is it possible for me, someone with very limited mechanical knowledge of the KLR - to take the KLR apart to the point where I can take the engine block off so that I can get it welded. WITHOUT taking the engine - just the block itself - so that I can get it to a welder and weld the cracked sump basin.

If its is, can anyone recommend a tutorial, or a useful youtube video?
(I already have the Clymer manual, and I will be searching myself, but I think its good to ask other people - you never know what kind of information is out there that I might not be able to find myself)

Also what kind of tools would I need? Other than the stock tools?

Thank you in advance guys!

Why take the engine out just roll the bike into the welders shop and lay it over. Drain the gas and oil of course.

Do you have a plan to fix the drain or are you just going to see what the welder can do?

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
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