crank and motor casings gen1 klr - 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 4 Old 08-04-2017, 03:08 AM Thread Starter
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Join Date: Aug 2017
Location: Belgium
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crank and motor casings gen1 klr

hello again ,

Another question, I looked for anwers here first but I couldn't find a definitve answer.

I just bought all bearings for the 1987 klr. After that I noticed a small crack in the casings...yeah right

This made me look towards replacement casings, but then I found a piece of info that said that the crankshaft is unique to this year for the 1987 model. Then I verified part numbers for the bearings, the right side bearing for the crank is the same as the 1996 model gen1. The left bearing can not be bought and comes with the left crank cheek?!

I know the crankshaft is different as from 1988 and changed a second time as from 1996 as are the casing from 1990. This leaves me a bit puzzled...

Do I weld up the casings? It is only minor damage or do I go to a newer 2nd hand lower engine from 1996?

Again all insight is welcome.

cheers Bart
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post #2 of 4 Old 08-04-2017, 09:10 PM
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Join Date: Nov 2009
Location: Lander, Wyoming
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barty,
I believe that there are zero dimensional differences in the 1987 vs newer crankshafts or cases.
There are a couple of crankcase reinforcements, as seen here,
http://www.klrforum.com/1987-2007-wr...nk-case-2.html

As to the crankshaft difference, I believe that it is the size of the oil port at the junction of the RH main shaft to the RH flyweight. My 1987 had the same oil pressure as was listed for the KLR600's. Which is actually a good thing, imo. But you can read all about that here,
http://www.klrforum.com/1987-2007-wr...-ya-got-5.html

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #3 of 4 Old 08-16-2017, 07:05 AM Thread Starter
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Join Date: Aug 2017
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ok so basically I can use engine cases from all years to fit the 1987 crank?

I came across this video on you tube from a guy who shows the crank can move around quite alot from left to right. I must admit that upon dismantling my engine I could move in the same way. Is that even normal?

https://youtu.be/DIuv-8_CJ64"]https://youtu.be/DIuv-8_CJ64

you'll have to copy and paste the link into your browser (not enough posts yet)

cheers bart
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post #4 of 4 Old 08-16-2017, 10:04 AM
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Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,336
Quote:
Originally Posted by barty View Post
ok so basically I can use engine cases from all years to fit the 1987 crank?

I came across this video on you tube from a guy who shows the crank can move around quite alot from left to right. I must admit that upon dismantling my engine I could move in the same way. Is that even normal?

https://youtu.be/DIuv-8_CJ64"]https://youtu.be/DIuv-8_CJ64

you'll have to copy and paste the link into your browser (not enough posts yet)

cheers bart
Bart,
With the RH primary drive gear and nut tight I believe the movement would be restricted to only the clearance of the RH main bearing. Say .001 inch?
With the nut and gear removed, maybe .100 inch laterally?

The connecting rod needs to be kept pretty much centered under the piston, in the cylinder. And we wouldn't want the cam chain or balancer chains wearing on the sides of the sprocket teeth.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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