685 kit upgrade - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 42 Old 08-28-2012, 12:19 PM Thread Starter
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685 kit upgrade

I have the unfortunate luck of getting a oil burner but I like my klr too much to get something else, so I am looking for lessons learned on upgrading to a 685 Shultz kit. Any input appreciated.

Edit: already searched forum but looking for those who have done it and any lessons learned, not looking to open the debate whether it is necessary...

Fradsham
'08 klr

Last edited by fradsham; 08-28-2012 at 12:32 PM.
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post #2 of 42 Old 08-28-2012, 03:15 PM
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Add another to the interested in hearing peoples experiences. Mine turned into an oil burner basically overnight.

Does the engine need to come out of the frame to get the jug off? Did you go local to get the machine work done, or order from a vendor and swap cylinders with them?
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post #3 of 42 Old 08-28-2012, 09:13 PM
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Add another to the interested in hearing peoples experiences. Mine turned into an oil burner basically overnight.
Mine was another over nighter. For the 1st 3,000 mile or so, not a drop. since then, it's been a half-pint, more or less, every gas fill up. Thats' a half -pint every 200 miles, or a quart every 800. Roughly. There's some variability depending on how much time I spend above 4,000 rpm: seems to take more oil when I run higher speeds. The 685 kit may be a good project for this winter. OTOH, I may just simply continue to buy oil. It's almost like riding a 2-stroke again, LOL!!
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post #4 of 42 Old 08-28-2012, 09:46 PM Thread Starter
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Mine was another over nighter. For the 1st 3,000 mile or so, not a drop. since then, it's been a half-pint, more or less, every gas fill up. Thats' a half -pint every 200 miles, or a quart every 800. Roughly. There's some variability depending on how much time I spend above 4,000 rpm: seems to take more oil when I run higher speeds. The 685 kit may be a good project for this winter. OTOH, I may just simply continue to buy oil. It's almost like riding a 2-stroke again, LOL!!
Same symptoms for mine, wonder how many more?
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post #5 of 42 Old 08-28-2012, 10:38 PM
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Mine is a 08 oil burner aswell, but only on the hiway. Lately since we had our brand new baby my trips have slowed down so just riding to work I don't go over 60kph. Never burn oil anymore. The way I looked at it back when I was going to do the 685 kit was it was close to $1000.00 dollars and no real performance gains. It would just stop burning oil. For a grand I can buy a ton of Rotela T. So I didn't bother with the upgrade. Sure I need to add a ltr every 1200km if I run hard on the hiway but that's like a $3 dollar ltr of oil. So I'll live with the oil consumption. With the money I save on gas with the bike the oil is nothing.



'Life's Journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways,totally worn out, shouting, 'Holy shit .... What a Ride!
Cheers, Nick
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post #6 of 42 Old 08-28-2012, 10:39 PM
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Fradsham, my bad. I just re read your original post. Yeah my post was more of a rant then a lessons learned post.



'Life's Journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways,totally worn out, shouting, 'Holy shit .... What a Ride!
Cheers, Nick
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post #7 of 42 Old 08-29-2012, 06:05 PM
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The way I looked at it back when I was going to do the 685 kit was it was close to $1000.00 dollars and no real performance gains.
Odd, I've only seen comments about lots of power gain, as in far more than there should be for a 34cc increase in displacement. And $1000?! Maybe it has really changed that much, but on Eagle Mike's site, it is $410 with the cylinder exchange.

Mine went from using a half quart every 2000 miles, to using a half quart in 100 miles. I'm not sure how it isn't fouling out the plug and dripping oil out the exhaust, but it's not.
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post #8 of 42 Old 08-29-2012, 09:20 PM
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Odd, I've only seen comments about lots of power gain, as in far more than there should be for a 34cc increase in displacement. And $1000?! Maybe it has really changed that much, but on Eagle Mike's site, it is $410 with the cylinder exchange.

Mine went from using a half quart every 2000 miles, to using a half quart in 100 miles. I'm not sure how it isn't fouling out the plug and dripping oil out the exhaust, but it's not.
Well when you add piston rings gaskets and shipping on top of the price of the head. It starts adding up. Unless I'm mixing this up with the 705 kit. I did homework on that one aswell. Maybe the $1000.00 quote was for that. It was a while ago I looked into it. But eitherway I still never heard alot but any big performance gains out of either kit



'Life's Journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways,totally worn out, shouting, 'Holy shit .... What a Ride!
Cheers, Nick
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post #9 of 42 Old 08-29-2012, 10:10 PM
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Well when you add piston rings gaskets and shipping on top of the price of the head.
Wouldn't start going after the head just yet, just the cylinder. The kit comes with the head gasket, the base gasket, the cam chain tensioner gasket, basically everything short of head studs.

Quote:
Unless I'm mixing this up with the 705 kit. I did homework on that one aswell. Maybe the $1000.00 quote was for that.
Quite possibly... Yup, the 705 with the sleeve and the ported head is looking to run 1060 plus shipping with the machine work.

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I still never heard alot but any big performance gains out of either kit
http://www.patmanracing.com/klrdyno.htm


Looks significant to me... Dyno sheets with headwork look even better, but I'll pick up a set of wheels and knobbies for my tarded DR or buy a KTM LC4 before I really start chasing HP on the KLR. I'm doing it primarily for the oil consumption. I really don't like carrying oil with me, and a big day for me, could go through the full oil capacity of the bike, much less a weekend adventure.
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post #10 of 42 Old 08-30-2012, 05:35 AM
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I got my 688 kit from Wyman, it was $420 shipped, of course the head work, KLX needle, ect added up,, But I wanted to do it all while I had it apart. It was around $1200 for everything. You pull the jug inframe, heck it takes longer to get to the head and jug than it does to pull it. The most difficult part is getting the jug past the rings, just take your time, and it would be easier if you had someone to hold the jug while you worked the rings in. I did it by myself,, but I would have liked to have another set of hands. I have not been able to ride it yet, I tore up my toe pretty bad, and can't get it into a boot so the riding part of the break-in has to wait.

Tom
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