Join Date: Mar 2011
Location: Meadow Vista, CA
I just recently (finished putting back together about a month ago) did the 685 kit and Eagle Mike did the machine work on the cylinder and head. My 05 had about 38,000 on it, burned a lot of oil especially at highway speeds (not unusual), I was also having some twitchy carb/throttle/not sure issues so I decided to take the plunge. I will say that I am pleased with the results.
Two weekends ago I did almost 1,000 miles of highway and dirt (considerable amount of highway that I usually try to avoid but we had to get there somehow). Before the upgrade, I would carry a quart with me on a typical long weekend ride (with usually minimal long highway miles) and I would have to top it off every day. The last ride I am happy to say, the oil is still at the top of the site glass. It runs better than ever with a lot more low end power-I'm not sure if that is because of the slightly larger displacement but my guess is that the whole top end was tired before and it's fresh now. Even stock displacement rebuild would have probably had similar results.
The carb issue I had is totally nonexistent now-not really sure why but I'm not looking a gift horse in the mouth on that one.
The only issue I'm having now is a clicking sound that wasn't there before, I suspect that it is related to the KACR on the exhaust cam (its driving me nuts but no detriment to performance at all), I ordered a new spring for it so we'll see if that helps. I even took the valve cover off at first camp to double check that nothing was flopping around in there, rattled the KACR a bit and the consensus was that it was the likely culprit.
Installation of the kit was pretty straightforward, I did have an ex-aircraft mechanic buddy help with the disassembly/reassembly who had also just done his own 08 which is a plus. It fired up immediately after I got everything back together-I was pleasantly surprised.
So-with that long-winded response, I think it was money well spent and a lot cheaper than a new bike.
Incidentally mine is an 05, 39000 miles, Eagle KLX needle clip on 2nd slot with no shim under the clip, Lexx silencer, 142 main, 685 kit, machined head/valves (Eagle).
BTW, valves checked out fine, (I went that route in search of the clicking noise)-right in the middle of the tolerances.
So that's my 685 story.