Bottom end rebuild - 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 08-27-2019, 04:21 AM Thread Starter
1st Gear
 
Join Date: May 2019
Location: Lake Macquarie, NSW, Australia
Posts: 36
Bottom end rebuild

As reported earlier on this forum the input shaft bearing behind the clutch has failed on my high (280,000km) mileage bike.

I'm looking for the collective wisdom of the forum as to what work I should now do to the bottom end of the motor given I need to split it. My thoughts are to:
(I) replace all gearbox and balance shaft bearings
(2) inspect mains and big-end but if all good leave well alone.

If the big end needs doing I'll pass that on to a professional, but are the main bearings practical to change myself?

Also are there any other high mileage failure points I should consider doing whilst it is open?

Does the above seem sensible plan? I'd like to resurrect the current motor but don't want to spend silly money doing it.

Thanks in advance - all advice and opinions will be gratefully received

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post #2 of 4 Old 08-27-2019, 11:05 AM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,466
Sounds to me that you have things well under control.

The LH crankshaft main roller bearing is not sold separately of the LH main journal or crank assembly in the USA. Most shops couldn't properly align the balancer or cam sprockets, I guess.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting

Last edited by pdwestman; 08-27-2019 at 07:49 PM. Reason: spelling
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post #3 of 4 Old 08-28-2019, 01:23 AM Thread Starter
1st Gear
 
Join Date: May 2019
Location: Lake Macquarie, NSW, Australia
Posts: 36
Thanks for that. I had a vague memory from a different engine rebuild in the past there was a problem doing the mains - that must be what it was.

Out of interest, with all your experience, have you ever come across a KLR with failed/failing main bearings after high mileage?

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post #4 of 4 Old 08-28-2019, 03:55 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,466
I have no personal experience with any failed crankshaft main bearings or bottom rod bearing on any KLR in my area. But most Wyoming, USA riders are not high mileage riders in general.

I have only seen pics of a couple failed LH crank roller bearings on the forums & facebook. And seeing more and more reports of 150,000 / 200,000 and even one 250,000 + mile KLR engines still in service.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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