Small end of conrod chewed! - 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 3 Old 07-05-2008, 03:05 PM Thread Starter
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Small end of conrod chewed!

Long story made short. Ran out of oil (lack of oil plug). Cam surfaces OK. No vertical movement of crankshaft (lower end feels OK). The rings/piston shot. Bought 685 kit from Schnitz and had cylinder bored out. But....

When I went to replace the piston the wristpin didn't want to come out. Turns out the surface on the conrod where the wristpin sits is scored. Can I get this surface machined/sleeved or do I have no choice but to get a new conrod? I really want to hear that I can have it machined (and better yet, with the conrod still in the bike).

Advice please!
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post #2 of 3 Old 07-08-2008, 11:13 AM
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Is there a bushing that can be pressed out and replaced? Otherwise I'd say you're looking at a rod-out job.
post #3 of 3 Old 07-08-2008, 02:06 PM
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Join Date: Nov 2007
Location: Corpus Christi, TX
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A quick check of Clymer indicates the upper con rod is bored only and not bushed. So you're surely looking at a new con rod.

I'm sure it could be bored and bushed, but your probably far better off with a new one particularly since your're going to the expense of the 685 kit. There is very probably some minor damage to the lower end that might come back to bite you anyway.

Last edited by BIGIRON; 07-08-2008 at 02:08 PM.
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