ACR Failed and broke the valve cover - 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 15 Old 08-24-2015, 09:21 PM Thread Starter
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Location: Delmar, NY
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ACR Failed and broke the valve cover

This is my buddy's KLR 35,000 miles, I'm taking care of it for him. Ha, How am I doing? It seems a few over on the FB KLR page think I may be ok removing the rest of the ACR and replacing the valve cover? Your thoughts? I've only wrenched on BMW's so any leads on KLR wrenching is much appreciated. I also have a problem with the bike only starting when I jump the solenoid. Darn couldn't post a picture because I'm a newbie.

Thanks, Andy
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post #2 of 15 Old 08-24-2015, 09:44 PM
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Music Man,
You/we NEED to get the attention of Tom Schmitz or klr4ever or 650stew, one of the moderators of this forum. So you can e-mail your pics to them or You Need to rack-up 15 postings and then post your own pics. Sorry.

Sorry that your buddys bike has trashed the KACR, but I haven't seen a KACR destroyed, that didn't 1st, run too low on engine oil, destroying the RH Exhaust camshaft bearing, allowing the RH end to flail around, before destroying the KACR. But it is theoretical possible.
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post #3 of 15 Old 08-24-2015, 09:55 PM Thread Starter
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I do have a bunch of photos. The person who was taking care of the bike for him before me let it run out of coolant, he kept riding it..so much that it go so hot and collapsed the coolant hoses and they had to be replaced. When Chris got the bike back after some repairs (i'm not sure what was done) he noticed there was a faint knocking he hadn't noticed before. I was at a BMW rally a few weeks ago and I was hoping to get another KLR rider who was there to listen to it but it was too late, I was about 5 miles from the rally site when I heard a pop, I only lost power if I decelerated, bike would stall, so I kept it going fine at 40mph, then I noticed the smoke in rear views, then I noticed my right pant leg was soaked in oil. Made it back, with what seemed to usual power as long as I kept throttle. Investigated and noticed the cracked valve cover and then the KACR broken in half. I still had oil in sight glass.

Last edited by Music Man; 08-24-2015 at 10:06 PM.
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post #4 of 15 Old 08-24-2015, 10:32 PM
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Music Man,
This is what drives me 'nuts' about internet repair, it goes from, "it broke" to, it "wasn't an oil problem" it was a "coolant problem", which I personally doubt! BUT, I CAN'T see it! YET!

A little help from the 'moderators', please!

I'm trying to drive up your post count. Keep talking. I or someone will respond, I haven't had lunch, much less dinner!
I think will go have some dinner, good night!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 15 Old 08-24-2015, 10:41 PM Thread Starter
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enjoy your meal
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post #6 of 15 Old 08-25-2015, 08:25 AM
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enjoy your meal
My contribution to your "post" count.
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post #7 of 15 Old 08-25-2015, 10:52 AM
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Andy's pictures:







[

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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

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post #8 of 15 Old 08-25-2015, 10:59 AM
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Based upon the number of reports of KACR failure (it's uncommon, but I attract disaster) and folks saying that they removed their KACR and had no problems, I removed mine.

I have had problems with occasional kickback while starting. Also, if the piston stops on the verge of a compression stroke (don't it always?) I will have to bump the starter to get things going, as there's not enough ooomph for the starter motor to push it through. The battery is new, in good shape, and charged. It always starts on the second bump. This is when cold. Hot is no problem.

Sometime this week I'll be pulling the tank off to install a different banjo bolt at the head. When I do that I'll be putting an exhaust cam with a KACR back on it.

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 #9 of 15 Old 08-25-2015, 11:14 AM Thread Starter
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Thank you Tom for posting the photos!
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post #10 of 15 Old 08-25-2015, 07:56 PM
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Music Man,
I'd like to see 2 pics of the R.H. Exhaust camshaft bearing.
1st Assembled, as is. I can't quite see what we Need, in pic 1. Elevate the view, 30 degrees.
2nd with R.H. Exhaust Camshaft Bearing Cap Removed, and turned Up-Side Down.
Show us the bearing surface.
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