Cracked a piston skirt - 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 14 Old 09-08-2018, 03:13 PM Thread Starter
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Cracked a piston skirt

Hey all - I was careless when working on our 2004 KLR engine, and managed to put a crack in the piston. I imagine I'm going to have to replace the thing, but was hoping someone would tell me otherwise!

Thanks for any help
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post #2 of 14 Old 09-09-2018, 10:37 AM
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Replace it.

2016 KLR 650
2017 BMW S1000RR (traded in for
2018 Ducati V4S
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post #3 of 14 Old 09-11-2018, 01:31 PM
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... shortest thread ever...

How'd you careless-crack it (I might learn something)???
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post #4 of 14 Old 09-12-2018, 05:28 PM
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If you don't replace it I'll suggest your engine will have about 5 minutes of life.

You will want to use a new piston & ring set for 2010 & Newer if using OEM Kawasaki parts. Older parts are discontinued or superceded to newer parts.

Eagle Mike, Schnitz Racing & Wossener are 3 highly recommended bigger bore choices.

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post #5 of 14 Old 09-12-2018, 05:49 PM
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Originally Posted by KLRCraig View Post
... shortest thread ever...

How'd you careless-crack it (I might learn something)???
I'll take a stab at a guess.....Since the connecting rod looks like it's still connected to the piston, The crank rotated and the skirt jammed/impacted the block deck.

If the piston DID impact another part of the engine, (block or an internal part especially) inspect that carefully for damage also.

2016 KLR 650
2017 BMW S1000RR (traded in for
2018 Ducati V4S
1983 GL1100 Goldwing
2017 Yamaha R1
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post #6 of 14 Old 09-13-2018, 12:06 PM
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As others stated there is no choice but to replace it. The big question is to do a re-bore or not. Going to a larger bore at this time will give you more power and better oil control. You've already got the bike/engine apart, right?
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post #7 of 14 Old 09-13-2018, 02:01 PM
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You can take a piston like that, cut the cracked part off, clean it up, chrome plate it and use it for a paper weight/pencil holder. But, you will need a new one for the bike. I like all three of the ones suggested by Pdwestman above.
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post #8 of 14 Old 09-13-2018, 04:56 PM
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With all the sincere and valid advice above . . .

A TRUE KLRista (aka, Frugal Motorcyclist) would drill tiny holes at the end of each crack to prevent their propagation, and . . . re-use the piston!

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post #9 of 14 Old 09-16-2018, 12:16 PM Thread Starter
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Hey folks - sorry for being out of communication - I thought I’d get flagged if anyone responded here, but I guess not! I went ahead and replaced it to be safe - thanks for the heads up
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post #10 of 14 Old 09-19-2018, 09:55 PM
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Quote:
Originally Posted by jsnfng View Post
Hey folks - sorry for being out of communication - I thought Id get flagged if anyone responded here, but I guess not! I went ahead and replaced it to be safe - thanks for the heads up
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