may be of interest - 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 67 Old 08-05-2014, 11:24 AM Thread Starter
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Join Date: Mar 2011
Location: San Pedro, CA
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may be of interest

Been a member for a while and enjoyed the forum a lot. Haven't had anything happen that was worth a new thread until now. My '02 has about 30k on it and has been the soul of reliability throughout a trip to Alaska several trips to San Francisco and daily commuting. Recently I became possessed and ran it down the freeway at about 95mph when I exited it was running abnormally hot and wouldn't idle. The next day I took it to work and when I came out there was a lot of oil coming from the air box. Built my own leak-down tester and it wouldn't hold ANY pressure, even blew into the adapter and it wouldn't hold the pressure of my breath. When I tore it down everything looked about right for a motor with that many miles. When I took the piston off I turned it on it's side to have a better look and I heard something fall. After cleaning things for a while I looked at the piston again and found this:

What amazes me is that it all stayed together enough to get me home. This is one of the things I really like about this bike.I think I wanted to do a 685 kit anyway.
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post #2 of 67 Old 08-05-2014, 11:42 AM
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If you want a stock piston to tide you over for a while I've got one with about 20K miles on it.

Yours if you want it; I'm local to you.

Tom

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On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again. -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 #3 of 67 Old 08-05-2014, 01:56 PM Thread Starter
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Thanks for the offer, it's the sort of kindness that is typical of the people here, however, I'm going to wait until I can afford the kit. I've got a '68 Beemer that's running well so I'm not completely without a ride.
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post #4 of 67 Old 08-05-2014, 02:00 PM
Pretty in Pink, dunno why
 
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Bings in the knees!

Cool, holler if you need anything.

Tom

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On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again. -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 #5 of 67 Old 08-05-2014, 10:14 PM
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I had that same thing happen to my turbo Subaru. It cost me about $7000 to fix it (including some upgrades). Ouch! Good luck with the 685 kit!!
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post #6 of 67 Old 08-06-2014, 09:27 AM Thread Starter
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Thanks. Have to say again how amazed I am that the piece didn't get loose in there and cause a lot of damage. Love this bike.
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post #7 of 67 Old 08-06-2014, 04:42 PM
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If you are willing to undertake an experiment, it would be interesting to hear the results. The oil return holes in the oil dam groove and the oil ring groove seem very small for a piston of this size. Comparing to much smaller pistons, the KLR return hole area is far smaller than pistons such as a GS350 twin. Given the bore circumference difference, this is surprising. I've been hoping to try drilling the oil return holes to a larger size to see the effects on high RPM oil consumption.

If you were to obtain that good used piston, inspect the rings for signs of chrome flaking and do a deglaze hone. Usually, used rings in decent condition will reseat with a hone.

I'm hoping to have a candidate one day as will only cost me a head gasket to try. If, as seems possible, we can help things by drilling the oil return holes to reduce oil consumption.

You may wish to check to see if you're lean at wide open throttle as that would make the heat condition worse and increase the chances of breaking a ring land. Could simply be the luck of the draw combined with high loading an perhaps some ring/ring land wear.



Quote:
Originally Posted by Tom Schmitz View Post
If you want a stock piston to tide you over for a while I've got one with about 20K miles on it.

Yours if you want it; I'm local to you.

Tom
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post #8 of 67 Old 08-06-2014, 05:50 PM
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Quote:
Originally Posted by Normk View Post
...........................I've been hoping to try drilling the oil return holes to a larger size to see the effects on high RPM oil consumption.................
With enough drilling you may get the benefit of reduced weight and less vibration.
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post #9 of 67 Old 08-06-2014, 07:13 PM
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What is the score, GOmotor? 3? 4?

Your answer cracked me up so, by the rules I use, I lost. If I can make a response without laughing then the leg pulling goes on, if I laugh it's a loss.

At least 3 for you....



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With enough drilling you may get the benefit of reduced weight and less vibration.
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post #10 of 67 Old 08-07-2014, 09:45 AM Thread Starter
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That's an interesting idea and I really am giving it some thought, but I have to admit some reluctance to use an old piston (even in the interest of science) when a new one is only a few weeks away.
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