Head swap gen 1 to gen 2 - 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 28 Old 05-19-2016, 04:28 AM Thread Starter
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Head swap gen 1 to gen 2

Hi guys, new to this forum. I am getting my first Kawasaki tomorrow, a 1992 klr 650 Tengai. I bought it cheap as the engine has cracked outer casing and as far as I can tell the doohickey failed. But I have a 2008 model that needs a top end rebuild as the bolts that hold the camshaft down vibrated loose causing top end damage. So my question is could I use the head off the 1992 Tengai and bolt it onto the 2008 motor? Or has it changed too much that this would not work. Any help is much appreciated or if there is a thread regarding this already(I couldn't find anything searching). Thanks in advance, tom.
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post #2 of 28 Old 05-20-2016, 07:44 AM
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Just bolt it on. You won't have the port for the AIS but likely saves removing it.
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post #3 of 28 Old 05-20-2016, 03:59 PM Thread Starter
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Awesome thanks mate, I'll put some photos up of my tengai soon!
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post #4 of 28 Old 05-21-2016, 12:49 AM
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Quote:
Originally Posted by Tom dickie View Post
...................have a 2008 model that needs a top end rebuild as the bolts that hold the camshaft down vibrated loose causing top end damage................
Those bolts don't just vibrate loose. There has to be a story behind this. What happened?

Yes, Norm know what he is talking about. The old head will work.
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post #5 of 28 Old 05-21-2016, 02:28 AM Thread Starter
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My mate bought the bought the bike with 20xxx klms on it and rode it until at 28xxx klms it vibrated loose. We suspect the valve clearances were done and not torqued up properly before he bought it. Hence I have a goodbottom end!!!
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post #6 of 28 Old 05-22-2016, 02:56 AM Thread Starter
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Quote:
Originally Posted by Normk View Post
Just bolt it on. You won't have the port for the AIS but likely saves removing it.
Hi Norm, can you tell me what the AIS is. Also still waiting for the freight company to deliver my Tengai thanks, Tom.
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post #7 of 28 Old 05-22-2016, 12:42 PM
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Not to pre-empt Normk's response to your question; I think, "AIS" stands for, "Air Injection System," a latter-day pollution scheme (not required at all).

Correction and clarification, if needed, sure to come, and welcomed!
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post #8 of 28 Old 05-22-2016, 02:04 PM
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More than you want to know about the "AIS" (Air Injection System).

It is a pollution control system on gen2 KLRs only which dumps some extra fresh air (oxygen) into the exhaust manifold portion of the head during closed throttle deceleration to help burn the bit of unused fuel that gets dumped into the exhaust system when you close the throttle at speed.

On the gen2 head forward and to the left of the spark plug is a small silver tube bolted to the a hole in the head with a flange. That hole does not exist in the gen1 head. The tube and a rubber hose leads back 50cm or so to a vacuum operated valve with two other tubes attached to it. One of these tubes goes back to the vacuum connection on the carburetor which also feeds a vacuum line to the vacuum operated petcock. YOU NEED TO CAP OFF THIS VACUUM EXTRA CONNECTION AT THE CARBURETOR.

The last tube connects into the main backbone tube of the frame and gets fresh air through a small filter at the lower end of the backbone below the seat.

Those three tubes and the vacuum operated valve are not used with the gen1 head and can be removed. DON'T FORGET TO CAP THE EXTRA VACUUM CONNECTION AT THE CARBURETOR.
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post #9 of 28 Old 05-22-2016, 02:32 PM
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It can be helpful to put a location on your profile as sometimes someone is just up the road and can offer a contact.



Quote:
Originally Posted by Tom dickie View Post
My mate bought the bought the bike with 20xxx klms on it and rode it until at 28xxx klms it vibrated loose. We suspect the valve clearances were done and not torqued up properly before he bought it. Hence I have a goodbottom end!!!
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post #10 of 28 Old 05-22-2016, 05:02 PM Thread Starter
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Thanks for the info! I will probably have more questions lol! I am in Canberra, Australia if anyone is near me. Hopefully get the bike today. Thanks, tom.
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