2002 KLR 650 Parts Bike teardown - 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 01-08-2019, 11:50 PM Thread Starter
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2002 KLR 650 Parts Bike teardown

Hello all,

After buying my 2005 Bike I had decided to keep an eye out for other cheap KLRs. Well I found one for $350 that the description said it had a broken connecting rod. For the price it came with all the plastics and a bunch of little parts that I was missing from my 2005. So I figured I would easily get my moneys worth out of it. Once I got it I started tearing it apart a noticed that the doohicky had broken, thinking this might be the only problem with it I decided to see why it had no compression. I had all the covers off and thats when I noticed that the intake cam gear was turning, but the cam itself was not. The cam alignment pin had sheered off. I decided to pull the cam off and this is what I found:
https://imgur.com/a/gv8iyzQ



Is this head toast? If it is, I'm not really bothered but I am interested in economical options to get this bike back up and running for my buddy to ride.

Last edited by Tom Schmitz; 01-09-2019 at 10:37 PM. Reason: Add cuppla picture
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post #2 of 14 Old 01-09-2019, 12:34 PM
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The intake cam gets oil Before the Exhaust cam via the copper oil pipe. So how bad are the exhaust journals?

Engine Dynamics can install precision insert bearing shells into that head & refurbish/replace the valves, seats and seals as needed.
Give them a call or e-mail with pics, ENGINE DYNAMICS

pdwestman
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post #3 of 14 Old 01-09-2019, 04:03 PM Thread Starter
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I didn't take the whole exhaust side off but the one cam cap I did take off looked fine, and the top of the cam looked alright as well. I'll tear it down more soon. I'm worried that sending this head out to be machined with be crazy expensive, both in shipping and machining. Does anyone have any idea what their costs are like?
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post #4 of 14 Old 01-09-2019, 10:40 PM
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Ya know, I've seen worse. You might get some plastigage and see just how bad they are from a clearance standpoint.

I think that Engine Dynamics is about $225 to fix two exhaust cam journals, plus the shipping cost.

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post #5 of 14 Old 01-09-2019, 10:45 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Ya know, I've seen worse. You might get some plastigage and see just how bad they are from a clearance standpoint.

I think that Engine Dynamics is about $225 to fix two exhaust cam journals, plus the shipping cost.
I was thinking about doing that, but if you look at the third picture you'll see there is some material left from the cam, I have a replacement cam that looks good but I'm not sure how to clean up the journal surfaces before checking clearances. I imagine that shipping will be pretty rough, does anyone have any advice on how to ship something like this economically? I doubt it would fit in a USPS flatrate box.
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post #6 of 14 Old 01-09-2019, 10:56 PM
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No idea on the shipping.

As for checking the clearances I'd pop the new cam in there and check them. The cam was spinning when it quit so the journals are roundish. Usually they are so galled up that Stevie Wonder could see that they won't work anymore. Yours are still not bad looking so if you are looking for a cheap way to get it going, simply check them and if they are OK, run it. Don't rely on it for a round the world trip, but for farting around it might just do fine.

I've seem some pretty terrible stuff done to Astro vans and they keep chugging. We're talking shade tree here, not NASCAR.

Of course, if the clearances are bad, they're bad.
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Tom [email protected]

I lit a cigarette and dragged a smoking stand beside the chair. The minutes went by on tiptoe, with their fingers to their lips. -Philip Marlowe

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post #7 of 14 Old 01-10-2019, 10:15 AM
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Originally Posted by darkipod View Post
I was thinking about doing that, but if you look at the third picture you'll see there is some material left from the cam, I have a replacement cam that looks good but I'm not sure how to clean up the journal surfaces before checking clearances. I imagine that shipping will be pretty rough, does anyone have any advice on how to ship something like this economically? I doubt it would fit in a USPS flatrate box.
Are you suggesting that layer of different colored material on the RH bearing cap is steel from the camshaft? Try to stick a magnet to it.

From the cylinder mounting studs to tops of cam bearing bolts I measure about 7 inches of height. One would want at least 1 inch of padding below & above & put the head in the box upside Down.

I feel that $225 is dirt cheap for the work required. Heck people spend $400+ just to make them 7 lbs lighter & 15db+ louder!
But I would budget at least another $200 for valve seat, valve & valve seal refurbishing/replacement. Call them & discuss it.

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post #8 of 14 Old 01-10-2019, 06:57 PM Thread Starter
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Are you suggesting that layer of different colored material on the RH bearing cap is steel from the camshaft? Try to stick a magnet to it.
Ok, Ill try, it seems pretty welded to the surface though. There is a guy my friend took his CBR600R Motor to, I was thinking about having him look at the head first to see if he can clean it up some. He did some decent work for my friend.

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From the cylinder mounting studs to tops of cam bearing bolts I measure about 7 inches of height. One would want at least 1 inch of padding below & above & put the head in the box upside Down.
Alrighty, Ill keep that in mind.

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I feel that $225 is dirt cheap for the work required.
I agree completely that $225 is pretty damn cheap, Im expecting to be reemed with shipping costs though, if I was local and not all the way across the country here in Florida then they would have my head already, hah.

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Heck people spend $400+ just to make them 7 lbs lighter & 15db+ louder!
Is that just bigger valves and lighter valve material? Or are they machining a ton out of the KLR head? That seems kinda crazy, I dunno that I would ever really think about a KLR getting big investment performance mods, they seem more like a trusty work horse as opposed to a crotch rocket.

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But I would budget at least another $200 for valve seat, valve & valve seal refurbishing/replacement. Call them & discuss it.
[/QUOTE]

Yeah, this is where it gets expensive, I mean, I dont have much into the bike, I got a full doohickey kit for $100 local. So Im only in it about $450 currently.

Thanks for all your help and advice as always guys.
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post #9 of 14 Old 01-10-2019, 07:35 PM
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A $400 exhaust system is about 7 lbs lighter & 15db louder. And don't believe any of their HP increase claims!

I was only talking refurbishing of standard valves, seats & new seals. If the owner doesn't remove them prior to sending the head, I'm sure you will be charged for at least removal. Do you have the proper equipment to Reinstall? Can you re-cut the seats, properly? Let the pros do it correctly, you will be money ahead.

I can't believe that you are now hesitating on the potentially $1000 - $2000 complete running 2002 bike. How does the body work look?
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post #10 of 14 Old 01-10-2019, 09:43 PM Thread Starter
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A $400 exhaust system is about 7 lbs lighter & 15db louder. And don't believe any of their HP increase claims!
Aaaaah I see now.

Quote:
Originally Posted by pdwestman View Post
I was only talking refurbishing of standard valves, seats & new seals. If the owner doesn't remove them prior to sending the head, I'm sure you will be charged for at least removal. Do you have the proper equipment to Reinstall? Can you re-cut the seats, properly? Let the pros do it correctly, you will be money ahead.
Yeah, I would send it in complete sans intake cam, however I would likely try and toss in the new cam that way they could ensure all the parts fit together, thats what most machine shops have asked of me for my car engines.

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I can't believe that you are now hesitating on the potentially $1000 - $2000 complete running 2002 bike. How does the body work look?
The Body isn't too bad, what im hesitating on is getting my money back out of it if my friend decides he doesn't really like it. There are a lot of KLR's for sale and older ones for under $1500 aren't even selling (Older being 2007 and under), I see them up for months. I can only assume they eventually take a lot less for them. If you want a cheap KLR, come to Florida haha.

Another big worry is that I havent seen what the crank case looks like yet, and that kinda worries me.

Last edited by darkipod; 01-10-2019 at 09:46 PM.
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