lots of smoke and heating - 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 5 Old 05-01-2010, 10:42 AM Thread Starter
Join Date: May 2010
Posts: 2
lots of smoke and heating

got my first Q for yall
i got a old 87 klr 650 a guy at work give me and let me tell ya she's in bad shape
but after clean the carb out it seems to run well and very strong but this thing smokes bad for the first 5 or 10 of riding it.
it even has oil built up on the back fender
the hotter it gets the less it smokes but after riding for a while maybe 45min are so it will over heat bad and let me add that the fan works and i pulled the thermostat to see if that was the prob and it did not help the pump seems to be working fine also.
all i do is play around the house with it so i don't wont to tear it down and find that its going to cost alot money to fix and then end up without a fast play toy. it does keep the mosquito's away tho lol

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post #2 of 5 Old 05-01-2010, 10:54 AM
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Join Date: May 2009
Location: Indiana/ Michigan line at the Lake
Posts: 1,586
Just stabbin' in the dark here.
With the age, I'm thinking crud buildup in the water jacket preventing effective cooling
or even preventing flow altogether. The engine overheats, cooks the rings, and
now there's a very hot engine that burns ridiculous amounts of oil.

Shouldn't cost much to use a rust removing radiator flush product.
Sounds like rings and a hone are in order at the least, or the next size piston
and fresh bore are in order to stop your smoking problem.

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post #3 of 5 Old 05-03-2010, 06:00 PM
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Join Date: Sep 2008
Location: Virginia
Posts: 1,263
The smoking engine when cold indicates valve seals. Typically, the smoke will go away as the engine warms up. You will have no 'skeeters around when it is cold.
Valve seals are not expensive, under 12 bucks for all. Your "revival" should include a valve clearance check, anyway, so you can do the seals and check your valve shim spacing. There is a vendor selling inexpensive 29mm shims I stumbled upon:


Look under "Motor Parts" on the left, click on valve shims.

The cooling issue is not so simple. It could be anything from a bad radiator cap to a plugged up radiator to a mouse nest somewhere. Some KLR's are temperamental in the heat department.

You might want to go back and check your carburetor settings. A lean carb will create a hot bike real quick. Check the spark plug. White plug = lean.

Last edited by vatrader; 05-03-2010 at 06:03 PM. Reason: kant spel
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post #4 of 5 Old 06-22-2010, 06:38 PM Thread Starter
Join Date: May 2010
Posts: 2
hey guy's thanks for the info i just got the time to do a compresion check on it and it's around 60 psi cold does any one know the min psi
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post #5 of 5 Old 07-01-2010, 07:48 PM
Join Date: Jun 2010
Location: Central california
Posts: 9
The KLR has a compression release at start up, designed so that the starter does not have to be so big to overcome the high compression, so doing a compression test won't tell you much.

I have an 88 that was doing just about the same thing with the oil burning issue. A lot of smoke at start up and she used a qt of oil every 150 miles. I went in and did a valve job and replaced the rings. But now there is a bit of a problem, because Kawasaki doesn't make the rings for it any more. I found a set on E-Bay. I had a Valve job done at a local machine shot for $75, I supplied the seals. Now she doesn't smoke at all and the oil burning is much less.
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