Head Mods - 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 6 Old 11-16-2007, 04:03 PM Thread Starter
Join Date: May 2007
Posts: 50
Head Mods

Hi All

Has anyone every milled the head on their KLR? I know on some motors this can really help in the torque and power deprtment.

How much? 100thou, maybe. Yet then the valves might start hitting the piston...

Just wondering if anyone has ever done this.

phil gates is offline  
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post #2 of 6 Old 01-05-2008, 03:02 PM
Join Date: Dec 2007
Posts: 7
if your still wondering about that yes it does make a differance i didnt shave my head alot just a c-hair .040 the thing that helped the most on that head was porting and polishing i highly recomend it.

Last edited by cantmiss; 01-06-2008 at 11:06 AM.
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post #3 of 6 Old 01-05-2008, 04:33 PM
3rd Gear
Join Date: Oct 2006
Location: Evansville, Indiana
Posts: 815
I think everything possible has been attempted with the KLR and nothing really works enough to justify the expense. Some guy created a big bore kit, but again, the gain doesn't really justify the expense. I forget how much the kit is, but I remember thinking "no thanks".
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post #4 of 6 Old 01-06-2008, 11:41 PM
2nd Gear
Join Date: Oct 2006
Location: SoCal
Posts: 103
The big bore kit includes a forged piston, better rings, and if you have them do the work, a better bore job than you get from Kawasaki. The result is less vibration, zero oil consumption, and improved torque and horsepower. The improvement is 4 to 5 horsepower.Price for the 685 kit is about $325. Piston has a coated skirt. Wrist pin is also coated.

The stage II head (also available from Schnitz Racing) includes porting and slightly oversize valves. It's beautiful work. Combined with the 685 and some light carb jetting you can get 43 RWHP. The bike just runs stronger everywhere. It's about a 9 to 10 HP increase over the stock bike.

No financial interest, just a very happy customer.

all the best,

eaglemike1 is offline  
post #5 of 6 Old 01-06-2008, 11:46 PM Thread Starter
Join Date: May 2007
Posts: 50
It seems the best results would be in the head. Eevn crate motors from the car manufacturers get the best results from after market heads. How much is that head from Schnitzs?
Thanx eaglemike
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post #6 of 6 Old 01-07-2008, 12:27 AM
2nd Gear
Join Date: Oct 2006
Location: SoCal
Posts: 103
It's about $625 for everything. First class. I know larryboy is running a 685.

Here's pic's of the 703 version of the big bore. This one requires an aftermarket sleeve. The sleeve is cryo treated. The tag on this one is about the same as the head, includes all labor. You can see the difference in wall thickness of the sleeve. No problems with fit in the cases.
703 on the left, stock on the right. 2500 miles on stock cylinder.

The 685 piston looks like this one, just a little smaller diameter.

I don't have any pic's right now of the head work. I have one at the shop. I'll try to remember to take a few shots tomorrow and post them.

all the best,

eaglemike1 is offline  
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