85 KLR 600 question! - 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 25 Old 12-30-2010, 08:42 PM Thread Starter
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85 KLR 600 question!

Hi everybody!

I have bought an old 85 KLR 600 cheap a couple months ago, in pretty fair shape. Two days ago i took it to the mechanic for carb cleaning and tuning and final chain adjustment, i went to pick it up today, and, he starts it up it kinda starts but dies quickly (due to being cold and not giving enough choke) after a many tries it wont start at all. Than we hear this knock, he said it went out of timing and hitting the valve i can turn the engine over but it stops when it hits the valve. He didn't charge me for the carb work and than i took the bike home took off the top and the side the timing chain does seem to be loose but other than that i dont see anything wrong with it.

Anyone could suggest what i should do?
I will provide pictures later!

Thx
Desperate to ride.
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post #2 of 25 Old 12-30-2010, 09:56 PM
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Evilman,
Bikes don’t kinda bend valves…… If the bike was out of time then the bike will hit the valve first time around……… These guys are awesome, keep adding details and they will help you find the problem….
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post #3 of 25 Old 12-30-2010, 11:56 PM Thread Starter
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He was trying to start the bike for a long time than got flooded took the plug out and went at it again! Could have that retard the timing?

It is for sure a valve is blocking the piston to go a full cycle! I took the top off and side cover off didnt see anything other than a fairly loose chain !

Could the chain tensioner got loose?

Any help welcome!
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post #4 of 25 Old 12-31-2010, 08:08 AM
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Cam chain / timing chain tensioner failure is common on the 600. So is chain wear, increasing the possibility for the engine to jump time. And bend valves.





At this point, I'd be pulling the tensioner out and checking that it is all intact and working. They are prone to fail, and many of the older ones were cobbled to function as manual adjusters, rather than spring tensioned adjusters. Your's may have been replaced with an after market component, and require manual adjustment. Or be shot and need replacement. i contend this is where frequent oil changes are evident. Oil that has "broke down", no longer offering the needed protection it was designed to provide, will allow excessive wear in the timing / cam drive system. The Mojave ATV's are notorious for cam system issues, which uses a similarly designed engine. Not all that unusual for a low mile engine to need a replacement timing chain, if it has not been well maintained.

On the flip side, someone will pipe up and claim they only change oil every 10,000 miles, replacing with used oil from the county hazmat recycling tank, and they never had a timing problem, so that couldn't be it.

One step at a time. Check your tensioner.

BTW, if you need anything for that bike, there is a complete, running when stripped, KLR 600 being parted out on EBAY right now. Email seller for additional information on other parts he has.

http://motors.shop.ebay.com/fishheadracing/m.html

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post #5 of 25 Old 12-31-2010, 08:21 AM
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When you took the head off, did the piston have a hole in it? Is the valve bent?
If no on both….
Why not put the head back on and retime the bike… then crank the bike over slowly by hand with the plug out to see if there is any interferences
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post #6 of 25 Old 12-31-2010, 08:56 AM
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It was running ok when you took it to the mechanic? Seems kind of weird that it would act like this after a carb adjustment and a tuneup... I wonder if he didn't adjust the doohickey (or try to) and possibly it was broken, so a piece of it fell off and might be locking the engine up? I'd have a look at that as well as the cam timing.

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post #7 of 25 Old 12-31-2010, 03:47 PM Thread Starter
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Ok Here are some pictures.
I found that little spring came off the KACR unit Kawasaki automatic compression relese!
I cannot tur it to ful cycle i think the exhaust valve not letting the piston come up all the way to the top!

Should i replace that spring?
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post #8 of 25 Old 12-31-2010, 03:57 PM Thread Starter
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Ok i just read in the manual that this could be a problem that the KARC spring gets damaged!
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post #9 of 25 Old 01-02-2011, 09:56 PM Thread Starter
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OK
I worked on it today and i have discovered that the exhaust valves are both broken! Bummer i need to take the engine apart!

Is it possible that i get away only taking the head off?
And do i have to remove the engine in order to take the head off?

thx
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post #10 of 25 Old 01-02-2011, 11:39 PM
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The head is easily removed w/o removing the entire motor.
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