Considering 685 kit in my 2000 KLR w/ 40k miles on the clock - 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 8 Old 05-26-2017, 05:37 PM Thread Starter
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Considering 685 kit in my 2000 KLR w/ 40k miles on the clock

I look at the KLR and keep thinking I cant quit you

So, Im seriously considering going for the 685, but wanted some of the collective wisdom on dos and donts since Im likely to attempt this myself.

Ill be rebuilding the carb while its off. The head/valves will be done. What else should I consider or definitely do during the process?

Is this foolish considering the mileage on the motor?

Any and all input is greatly appreciated.


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post #2 of 8 Old 05-26-2017, 06:59 PM
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Cabrito,
How does the bike currently start and run? Instantly and strong? or Reluctantly and weak?

How many miles to a pint of engine oil? 4000, 3000, 2000, 1000, 500? I'm sure you have read about the PDW oil control orifice.

I've read that the 661 kit is the 'smoothest', but do understand the natural lure of 'more power'.

If the head comes off at +40,000 miles, I advise All New Valves be purchased.
Have the head work done by a professional shop like Engine Dynamics or Import Automotive.
or
Have the ID 60 degree cut of the seat 1st. Then the OD 30 degree cut 2nd. Take the absolute minimum material off of the actual 45 degree valve seat face required. Re-cut either or both the 60 or 30 degree to achieve .9-1.0mm valve seat width. And then have the valve stem tips trimmed (maximum of .015-.020 inch) to allow thicker adjustment shims to be used initially.
The narrow valve seat contact face (.8-1.2mm spec) flows air better, seals better and therefore wears Slower.

The bottom end is good for 150,000-200,000 miles barring unforeseen errors.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 8 Old 05-26-2017, 07:16 PM Thread Starter
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The bike starts and runs great, but feels tired and is a chronic oil burner since I bought it 7 years ago with 11k on the ODO. The oil burning is just getting worse.. I usually add oil every 200-300 hundred miles when it's mixed city and freeway riding.

I don't know about the PDW oil thing, but I'll search it.

I'm not looking for power. I'm just looking to re-fresh it and keep riding it.

I would likely send everything to Eagle Mike to do the valves, and jug.

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post #4 of 8 Old 05-26-2017, 08:44 PM
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Good choice, Eagle Mike uses Import Automotive. I learned about I.A. thru EM's postings.

Links to my work and Tom Schmitz's follow up work,
http://www.klrforum.com/1987-2007-wr...mportance.html

http://www.klrforum.com/448425-post6.html (Toms Video)

Ride On!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 8 Old 05-27-2017, 11:52 AM
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Yep; sounds like the perfect candidate for a 685 and I'd send the whole works to EM as well.

Cheers,
Dave
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post #6 of 8 Old 05-27-2017, 02:10 PM Thread Starter
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Just spent the morning watching Tom's extremely helpful 685 overview and installation videos.

https://www.youtube.com/playlist?lis...MiQ-BWTLdBQhxI

Schnitz also has some decent instructional PDF's on their site.
http://www.schnitzracing.com/manuals...all-part-1.pdf
http://www.schnitzracing.com/manuals...all-part-2.pdf

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post #7 of 8 Old 05-28-2017, 09:35 AM
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Cabrito, I'm in the same boat as you since my bike is using more oil lately. I'm not chasing more power either, just want the luxury of not needing to add oil every couple tank-fulls. lol

Will be keeping an eye on this thread.
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post #8 of 8 Old 05-31-2017, 02:02 PM
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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.
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