Pre-'96 re-bore options - 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 11 Old 03-16-2018, 10:48 PM Thread Starter
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Pre-'96 re-bore options

So I've been enjoying my 1989 quite thoroughly for about a year now, after installing all the parts I collected some time ago before my return to Taiwan. I'm now looking at my next wrenching session, which was inspired by the old girl's excessive oil consumption. I'm looking to put a new piston in my cylinder. I have seen a lot of talk about the 685 bore kits around, but have also seen that they aren't safe for pre-'96 KLRs. I've also heard tell of a 1mm oversize piston which I have yet to find. I'm also looking to replace valves while I've got everything open, and so I'll need new valve shims while I'm at it. So in short, can anyone tell me my options for re-boring a pre-'96? Specifically an '89?
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post #2 of 11 Old 03-16-2018, 11:01 PM Thread Starter
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And to be specific, though I doubt it would make any difference, my KLR was originally the 650B Tengai back when it was first built. She was also likely brought directly here from Japan, so if there is a "Japanese" version of the KLR that differs in any way from what you guys have in the other parts of the world, that's almost certainly what I have.
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post #3 of 11 Old 03-17-2018, 11:22 AM
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Call Eaglemike and order a 661 kit ....the other option is to swap to a '96+ cylinder. The 661 is quite good an reports are that it has even less vibration than the 685....though both are better than stock.

https://www.eaglemike.com/KLR650-200...earlier_c2.htm

Dave
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post #4 of 11 Old 03-17-2018, 11:40 AM
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One could use the newest pistons, rings, pin & clips from Kawasaki Gen 2 (KL650-E) (2012 & UP) models.
Available in .50mm or 1.00mm over-size.

Or one could use the Eagle Mike 661cc JE piston & ring kit which was purposely manufactured for our older, thinner Gen 1 cylinder sleeves. It is only 1.00mm over-size also.

https://www.eaglemike.com/661-forged...-kit-661pk.htm


If one has easy access to 90+ MON gasoline one might opt for a High Compression Wossener Piston, in the 100.94mm size.

https://wossnerpistons.com/products/8523



If one acquires a 1996+ cylinder, one could fit the Eagle Mike 685cc JE piston kit onto your 1989 KL650-B1 Tengai engine. Eagle Mike does offer to exchange early cylinders for later cylinders.

Hope this helps.
(I am considering potential ease of access to OEM parts.)

pdwestman
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Last edited by pdwestman; 03-17-2018 at 06:18 PM. Reason: added (2012 & up)
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post #5 of 11 Old 03-17-2018, 02:25 PM
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Paul is correct and went into much more detail than I did. My only caution is to beware that the stock piston/ring sets won't have the advantage of the EM kits for lessened vibration and I trust Mike's ring quality better......I don't typically recommend the higher compression kits due to minimal power increases compared to the disadvantage of having to run higher octane fuel but it is certainly another option.



2 cents,
Dave
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post #6 of 11 Old 03-17-2018, 08:16 PM Thread Starter
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Cool. I guess I'll find out from Eagle Mike if he'll ship internationally. That's one of the tricky bits. I am a bit interested in the Wossner kits, though, as our lowest octane gasoline here is 92 octane. I usually burn 95 in my four strokes, and the 92 in my two stroke. Does the Wossner piston come with associated rings, gaskets, etc., or would I need to source those separately? It looks like it's just a piston to me, but I'm not the most keen observer....

I guess I'll check EM first. My doohickey is EM (the OEM doohickey wasn't broken and is now on my keychain haha!) Gotta see if he's got valves and such for me, too. Better to order it all from one source if it's gonna be shipped overseas.

Thanks, y'all.
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post #7 of 11 Old 03-17-2018, 09:22 PM
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I'll recommend the One Stop Shopping at Eagle Mikes!
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #8 of 11 Old 03-18-2018, 10:17 AM
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Quote:
Originally Posted by TaiwanMotoGuy View Post
Cool. I guess I'll find out from Eagle Mike if he'll ship internationally. That's one of the tricky bits. I am a bit interested in the Wossner kits, though, as our lowest octane gasoline here is 92 octane. I usually burn 95 in my four strokes, and the 92 in my two stroke. Does the Wossner piston come with associated rings, gaskets, etc., or would I need to source those separately? It looks like it's just a piston to me, but I'm not the most keen observer....
Be CAREFUL about your octane rating!

US gasoline octanes are determined by the average of the RESEARCH and the MOTOR method ratings.

US octane number = (Research octane number) + (Motor octane number); the sum divided by 2.

MANY foreign countries use only ONE of these methods, the one yielding the higher number, if I'm not mistaken.

Your Taiwanese fuel may accommodate the Woessner piston's higher compression; I'd find out before I stuck one in my engine. If I instead went too far, and got too much pinging, I'd consider doubling up on head gaskets EDIT: [or cylinder base gaskets as pdwesman suggests below] to lower compression ratio.
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Last edited by Damocles; 03-21-2018 at 08:02 PM.
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post #9 of 11 Old 03-18-2018, 07:00 PM
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Damocles,
Doubling up on head gaskets on a liquid cooled four stroke engine would be inviting either or both compression and / or coolant leakage, imo.

It would be safer to Double up on the cylinder base gasket, like the original Schnitz Racing 685 kits supplied, if truly needed for low octane fuel in underdeveloped countries.

But I'll bet the OP is going for one stop shopping at EM's. And won't need to worry about octane rating.
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #10 of 11 Old 03-19-2018, 12:36 AM Thread Starter
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Yeah, I think I'm gonna stick with Eagle Mike. He's got my valves and everything, it looks like. I'd like to swap seats and guides while I'm at it, but just valves should be ok if he hasn't got the other bits. Save on shipping costs if I stick to just one order from one supplier. Of course, I'll need valve shims after everything's put in place, but I'm thinking I'll just ship those domestically to some family and have them send over an envelope or something.
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