Big bore - 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 03-27-2016, 03:58 PM Thread Starter
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Big bore

Hi, With me doing a complete engine rebuild with new ballraces an stuff, I'm thinking of doing a big bore too.
I wondering how big a piston you can go using a standard liner?

The piston options on ebay seem to 97, 100 and 102mm.

I'm thinking the 100mm would be maybe a bit big for the standard liner, but I wont be doing many miles, prob only 500 a year.

Thanks
Ian
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post #2 of 15 Old 03-27-2016, 05:03 PM
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Ian H,
We Need More pertinent info Ian!

97mm is 1mm OS for a KLR600 cylinder. 3mm's too Small for even a standard bore KLR650!

Which engine are you working on and What Year is the cylinder that is On It? 84-86 KLR600 / 87-95&1/2 KLR650 / 96-up KLR650 has thickest liner at the base.

pdwestman
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post #3 of 15 Old 03-27-2016, 06:11 PM Thread Starter
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Sorry, lol. I forgot the manual I had is for the 600! I have both engines an barrels, and a few spares of each.
I'm rebuilding the 650 at the moment and assuming all the parts are there (I got the engine in several cardboard boxes of parts) I'll be using the 650!

Thanks again

Ian

Last edited by Ian H; 03-27-2016 at 06:14 PM.
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post #4 of 15 Old 03-27-2016, 11:06 PM
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All I can say is 685.....the most proven kit on the market!
BUT, the new piston Tom is showing does look nice...? I'd have to see how it handles itself before i would risk anything over the 685 imho.

Willys
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post #5 of 15 Old 03-28-2016, 10:42 AM
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Quote:
Originally Posted by Ian H View Post
Sorry, lol. I forgot the manual I had is for the 600! I have both engines an barrels, and a few spares of each.
I'm rebuilding the 650 at the moment and assuming all the parts are there (I got the engine in several cardboard boxes of parts) I'll be using the 650!

Thanks again

Ian
Quote:
Originally Posted by willys View Post
All I can say is 685.....the most proven kit on the market!
BUT, the new piston Tom is showing does look nice...? I'd have to see how it handles itself before i would risk anything over the 685 imho.
Ian,
The 685cc 102.5mm piston must be used in 1996 (650) and Newer thick based cylinders, from all that I have read.

The thinner skirted 1995 (650) and older cylinders will accept up to 101mm pistons, safely.

pdwestman
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post #6 of 15 Old 03-28-2016, 10:50 AM
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Yes i was assuming he had a 96 and up OR if he wanted he could resleeve it for the 705 sleeve which is the cat's ass imho, then bore to his desired width......the 705 sleeve is far wider at the bottom edges compared to all of the other sleeves and thus will long outlive them all. It's all money!

Willys
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post #7 of 15 Old 03-28-2016, 01:06 PM Thread Starter
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Hi, many thanks for the replies, any ideas how I could tell a 96> barrel from a 95< This engine was just a few boxes of parts theres two 650 barrels.

I'll have a measure see if one liner is thicker than the other.

I haven't got the money for re lining, would love to do it tho, I cant find a 102 piston in the uk, so i'll have to get stuff imported from the u.s.

There is a 101mm piston but would it make any difference?

Thanks again
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post #8 of 15 Old 03-28-2016, 01:29 PM
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Ian,
That depends on who made it, for what reason, with other improvements or not and how you put it all back together.

Wossner pistons are from Germany, I think. Link for your viewing pleasure.
http://www.klrforum.com/1987-2007-wr...tml#post316105
Thanks go to Damocles for the link.

ps, Sorry that the 'link with-in the link' doesn't work.

pps, Here is more recent link, http://www.klrforum.com/2008-klr650-...-~11-1-cr.html

pdwestman
Modify at "YOUR OWN RISK"!

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Last edited by pdwestman; 03-28-2016 at 01:49 PM. Reason: ps added / pps added
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post #9 of 15 Old 03-28-2016, 01:57 PM
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See page 8 of this .pdf: http://watt-man.com/uploads/KLR_Timeline.pdf

Contact these guys Wossner High performance motorcycle forged pistons and inquire as to the availability of an oversize piston that has a flat top.

I know that they have +1 and +2mm domed pistons that increase compression to ~11:1, but I know that they have smaller (+.01 and +.02mm) pistons as well.

You might be better served with a standard compression piston. Increasing compression will increase the stress on the engine a bit and that may be something you are not interested in.

I'm familiar with the US distributor, but not the UK distributor; product availability may vary.

Tom

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post #10 of 15 Old 03-28-2016, 10:52 PM Thread Starter
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Hi, thanks again for the links.

The increase in compression sounds like a plan, Ive already cleaned the ports out, and would save me getting the head skimmed.
The super unleaded in the uk is 97-99 octane so pinking shouldn't be much of a problem hopefully.

I think both my barrels are pre 96.

I can see the next week been expensive.......
Thanks

Ian
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