Was An Engine Teardown, now it's Frankenbike time! - Kawasaki KLR 650 Forum
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post #1 of 248 Old 10-17-2012, 01:27 AM Thread Starter
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Was An Engine Teardown, now it's Frankenbike time!

I'm going to tear down my engine, find out what is wrong, and decide how to best go about fixing it.

The background - While underway at 70mph it suddenly started to vibrate very badly. I pulled in the clutch and coasted to a stop. Upon dismount I found an engine covered in oil.

At the time, beside I5, I could not easily see the source of the oil. In fact, it was not until I was at the hotel that the tow truck operator delivered me to that I was able to examine the engine from a safe vantage point.

What I saw was a small hole/rupture in the case, a fair amount of oil, and a lot of fine aluminum particles. The sump had been full and was now down to about 3/4 full.

My first guess is that something associated with the balancer system let go.

Here are the initial pictures. Stay tuned.

My engine is not normally shiny. The oil covered the engine, the lower portion of the gas tank, the side panels, the exhaust, and both pant legs.

It's hard to see, but back in the shadows is a long, lifted cracked section.

Ready to go home.


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Last edited by Tom Schmitz; 02-04-2013 at 07:27 PM.
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post #2 of 248 Old 10-17-2012, 05:59 AM
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That does not look good. Do keep us posted and good luck!
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post #3 of 248 Old 10-17-2012, 06:01 AM
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Not good. Sorry to see that. From what you have told so far I'd be inclined also to think something in the balancer let go. I *think* that is in the general area.

Not that it matters since you'll be splitting the cases anyway, do you have a bore scope?

Keep us posted with photographic evidence and commentary.

Last edited by flash; 10-17-2012 at 06:20 AM.
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post #4 of 248 Old 10-17-2012, 06:29 AM
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Ouch! Think I'd be on the lookout for another engine...

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post #5 of 248 Old 10-17-2012, 08:12 AM
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And now we have proof that a KLR650 will fit in a S10 shorty...

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post #6 of 248 Old 10-17-2012, 08:13 AM
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Tom, sorry about your motor, the missing part and raised area of the case does not look good. Might be easier to dump a different motor in and have parts to sell.
Let me know if ya need so help.


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post #7 of 248 Old 10-17-2012, 08:25 AM
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That doesn't look good. I've got a 75 Goldwing here with the same symptoms. Had you done anything inside the engine lately?? Doohickey done??

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

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post #8 of 248 Old 10-17-2012, 08:34 AM
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Damn!!!! That is a huge disappointment for sure.....I feel for you.

As you already know what is in that location in the engine your guess is pretty good. The only thing left is to why it happened. Again Damn!!!

On a side note.....this type of issue is exactly why I will never allow someone else to beat on my bike as in a dyno run.....probably not the cause in this case, but what if this had happened while on the dyno. I personally would be more upset than if it happened like where it did happen, while you were riding it normally. Anything can cause issues like this but usually when pushing a bike to its limits not cruising down a road....sorry to say.

From what I can gather you are not a wild rider pushing your bike all the time showing off for your group etc like some do. Nothing wrong with that if that is your style by the way. But that is the sort of riding that usually results in this type of damage, over rev'ing etc.

Again sorry to see this happen and sorry to go on about dyno running.....lol.

Take many pics please so I know what to look for when I take mine apart again this winter to split the cases etc.

Thanks Tom....

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post #9 of 248 Old 10-17-2012, 08:56 AM
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how many miles on her ? did you do the doohickey already ?

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post #10 of 248 Old 10-17-2012, 09:04 AM
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Tom, I don't remember what year it is either......thanks.....

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