Hole in the engine case... - 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 6 Old 04-17-2010, 11:11 AM Thread Starter
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Hole in the engine case...

My sister who is admittedly not the sharpest screwdriver in the drawer when it comes to mechanical things recently bought a 2005 KLR. I have no history on the bike.

Recently her son (16yrs old) came back from a ride on the bike and said that oil was pouring from the engine case. Turned out there was a hole. They live on a gravel road and the stock skid plate was in place.

She took the bike to her local mechanic and had this to say:

"
Apparently KLR bolts come loose and one ended up in my oil and it blew out the bottom! Good thing we had the experts work on it, if we'd just plugged the hole the bolt would've blown the engine. There's also a random spring in there that needs fixed s...o I'm looking at $610. Whatever it takes, but I must say I'm disappointed in Japanese engineering! Ever heard of this happening?"




I personally have never heard of this and instead suspect it was the doohickey. But I am wondering what others think. So, on that note:


Thoughts?

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post #2 of 6 Old 04-17-2010, 01:01 PM
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Yep sounds like the worst case of a major doohickey failure. Considering one of the engine cases needs to be replaced, the price actually sounds reasonable. Go on bikebandit and price the engine cases and you'll see. Sorry to hear about her problem. Curious as to how many miles were on the beast?

John

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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post #3 of 6 Old 04-17-2010, 09:15 PM Thread Starter
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She says there's about 9,000 miles on the bike. She also thinks her mechanic might have called it a "rotor bolt", which would make sense.


Ahhh - if only the 'doo police had gotten there sooner

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post #4 of 6 Old 04-17-2010, 11:41 PM
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Can't see a rotor bolt coming loose.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

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post #5 of 6 Old 04-21-2010, 04:21 PM Thread Starter
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From my sister:

Quote:
update~ I got to see the insides of my KLR the other day and the bolt that was loose. He says it's a crank shaft bolt from the decompression spring on the cam that holds the crank seal container. He showed me where it was floating around and how lucky it didn't fry the engine!

Apparently I need to go look at an engine diagram, as I have no idea what she's talking about

You don't know unless you ask.

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post #6 of 6 Old 04-21-2010, 07:28 PM
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Sounds like it's in the top end, thus not a doohickey related failure. Probably not a "crank shaft bolt" if it's part of the compression release. Keep us up to date, love to understand failure modes, yep I'm an engineer!

Farkled probably WAY too much, but good 20' footer for sure. '96 KLR, '06 HD VROD, (girl friend hauler), '05 HD Electra-Glide, heh it's a HD and I'm old now ;-) and I'm proud of riding a 800+ pound bike at my age :-)
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