$320 KLR Project - 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 12 Old 08-22-2010, 09:26 AM Thread Starter
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$320 KLR Project

Please don't take this as any expert advise on wrenching, I have never done a job like this. So any advise would be accepted.

Scanning CL one day I came across this KLR only a few miles from my house. The ad read, just needs a $12 part but I don't have the time to put it in??. Price $1250. So I call the kid and take a look at it, complete bike but its not working. I asked the kid to describe the last time it ran or what happen when it stopped. "Ummm, well it kinda, I don't remember" and then my friend tried to fix it. So then I told him I would give him $500 but I wanted to check for DMV fees and he said ok and I took the vin#. At home I did a check and $140 of fees are due. I email he and said I could only give him $300. The next day he call and asked if I could go $320 because he wanted to buy a drum set?? OK I said have the pink ready and I will be over at 9am.


Maybe we can get lucky, so lets see what we have. First I want to pull the left side and check the Doo, now I only have about 4 weeks of experience with the KLR of just reading forums and up to now have read alto about the DooHickey.


After pulling the left outer case I can see it was in the weather a little, so what I think and lucky I guess they stop at this point was they relished they could not get the flywheel off.

It took some heat to free it up and stripped out one puller and then it came off.

Let me back up a bit, the motor would not turn over but it did move a bit back and forth.

Ok lots of slack in the chains and the Doohickey is just laying on the bottom and I see the broke spring.

Now I pick out the pieces and try to turn the motor and it still jamming so I guess the piston is hitting a valve, as loose as the cam chain is it must of jumped. So off with the head.

With the head off now it all spins free, it didn't appears that the piston hit hard because it looked pretty good as far as no big dents or chunks on top.



So for the final look over for the day I notice that the balance r sprocket on the crank is shot.


Now Im told that even though this part is listed as a separate part #12046 for $47 is that it can't be pulled off the crank and that I would need a complete crank. So maybe my next step is a crank off e-bay. This is where I'm at and any suggestion are welcomed.

So far,
Cost $320
Time 3 hours.
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post #2 of 12 Old 08-22-2010, 10:42 AM
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This should be fund to watch....

You don't know unless you ask.

Check out my website www.dantesdame.com <--- rides! rides! rides!
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post #3 of 12 Old 08-22-2010, 11:26 AM
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Talking $12.00 Part?

So, what happened to the $12 part fix?
Guess the kid wanted a drum set more than being up front with you?
Good luck on the project!
It may turn out to be a wise investment!
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post #4 of 12 Old 08-22-2010, 11:32 AM
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There are plenty of cranks for sale on ebay right now. Most of those cranks are just a few dollars mor than the cost of that gear. I just put a used crank in my motor after having the roller bearing on the left side go bad.
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post #5 of 12 Old 08-22-2010, 11:36 AM
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Looks like a cool project to me! Quite a bargain from the original asking price. Good luck with it and please keep us posted!

Cheers,
Stew
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post #6 of 12 Old 08-22-2010, 02:09 PM
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I think you made a good buy. You'll get it running, and it is a sweet looking bike.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
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post #7 of 12 Old 11-17-2010, 09:03 AM Thread Starter
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So since my last post I have about 8 hrs into the project. I went to the Eagle Mike tech day after the first opening of the motor after finding the balancer and Doo Hickey all jacked up. I asked about different options and had a few answers from, need a new crank, buy a bottom end and buy a complete motor. I like the last one, but then paying anywhere from $500 to $800 for a motor that I could just pop in sounds like a big gamble. Part of the reason for getting this bike was I thought $320 would be a good teaching bike to work on. So my choice came and I going for it, yep doing it myself. I have never taken on a job like this, yea I can do a Hodaka that has no cams or valves and I have been pretty far on a Harley with push rods and someone helping over my shoulder. Now this is also a new thing for my partner at the shop because he only knows Harley. So here we go.

I got the motor out and on the bench, during this I found the sub frame bolts have been up graded as well as the right foot peg.


Before the motor goes back I will get the frame all cleaned up and check all the wheels and swing arm bearings.

Trying to keep it all in order on the bench.


Here I have the right side off and the clutch.


I little checking of the parts, the oil screen had a bunch of debris and the clutch plates and basket looked pretty good but I found a broke spring in the back.




So this is where I'm at. I have been looking at parts on e-bay and will go visit Eagle Mike for some advise, one thing at least to me is that the factory repair book is pretty vague.
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post #8 of 12 Old 11-17-2010, 09:04 AM Thread Starter
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So a little more progress on the KLR. As much as I was hoping I would not have to split the cases its a good thing I did. With the crank in the motor all button up it was hard to feel all the slop in the rod, so the crank was more gone then just the balancer sprocket. I then also found the main crank bearing bad also with what feels like flat spots.


The bearing is a bit more special then my local bearing shop can get, outer race has a shoulder on each side.


and remember that broking spring on the back of the clutch,

well here is the pieces that were on the bottom of the motor.


So now I wait for the parts on order, I bought a use crank from a ebay seller that sells alot of KLR parts and Eagle Mike has had good dealings with. I got the crank and it looks very good for $85 plus free shipping. So while I wait I though I would do a little cleaning on the frame.








So that's where I'm at now. I will add up the time and how much I have spent for the next post.
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post #9 of 12 Old 11-17-2010, 09:06 AM Thread Starter
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So a member from another forum hooked me up with a lead that I had to take. OK so weighting all the options for the bike and cost I could not pass this up. With the old 93 motor after spending $85 for the crank and another $80 for the new bearing and a couple seals I know there is still much more to come, I know I need to find a new clutch basket, the head needs to have the valves done and even though the piston and cylinder look good if not I would probably end up buying one from a newer bike.

So here I am now with a 2004 motor for $625 and it was close enough 40 miles for me to pick up. The seller guarantee me with money back that it runs and is DMV clear.












I will probably get the 93 bottom button up with the new parts and try to sell to recoup some cost. As well as check out the other parts like the piston and cylinder and if in spec sell. We have all the tools to do the valves and the owner of the shop will show me how its done and I would like to gain that knowledge.

So with the new motor I will go and do all the checks of filters and screens and give it a good check over as well as the Doo.
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post #10 of 12 Old 11-17-2010, 09:07 AM Thread Starter
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I was able to get a little work done on the KLR this last week. Put in the new crank bearing and crank.


Timing marks on the inner balancer.


With the center button up worked on the clutch side.




At this point I will button up the clutch side noting that this unit needs a new clutch basket. I will close up what I can on the other side noting that it also need a new Magneto, it was ruined when we had to use heat to get off. I will sell of this lower end to try and recoup a couple hundred dollars maybe. I'm not really interested in the kick option so that will stay on the motor. I need to use a few parts off the 93 motor on the 04 motor like the carb and starter. So now before I put the new motor in I think I will service the linkage and then get going on the motor.
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