Cylinder identification '96 or newer? - 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 1 Old 12-10-2008, 10:29 AM Thread Starter
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Join Date: May 2008
Location: Arlington, TX
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Cylinder identification '96 or newer?

Is there a sure method for determining if a cylinder is a 1996 and up verses the 95 and older? I have a cylinder that I purchased to prep for a 685 kit install, and it was sold as a 96. 1996 is the first year that can take the 685 due to having thinner bore liners in the older models. My concern stems from it being a black painted cylinder and having a different casting mark on the front compared to my 1998 cylinder. I have only seen black engines in the older KLRs, late 80s and early 90s models.

Does anyone here know the casting marks to look for, or know the dimension of the old verses newer cylinder liners? I would like to find out for certain that this will work before I cart it off to a machine shop for boring and honing. If it is older than 96 I will want to get in contact with the fellow that sold it to me and ask him about it. I must use caution though, since as of right now I have no data to be sure that it is an older cylinder, and don't want to lodge false accusations. Even if it is older than a 96 it may still have been an honest mistake, not a fraud deal.

Thanks in advance for any help that comes my way.


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