Found an 08 needing engine work - Kawasaki KLR 650 Forum
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post #1 of 7 Old 02-28-2014, 06:47 PM Thread Starter
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Found an 08 needing engine work

Found an 08 and may be able to buy cheap. Problem is the head has been removed and the cams and bearing surfaces are damaged from lack of oil. Buying a new head and cams is out of the question, would have more in the bike than it's worth. Apparently no one has came up with an effective way to repair the head either. Not much on ebay for good used 08> heads and again cost prohibitive. Question is will a gen 1 head fit a gen 2 engine?
Wondering if I bought this thing would it be worth fixing or just part it out?
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post #2 of 7 Old 02-28-2014, 06:55 PM
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Depends on how cheap you are getting it for before you start. Is that the extent of the damage or just what you can see or what they are telling you??

And yes you can use a 1st Gen head on a 2nd Gen. You have to plug off the AIS port. (EDIT:at the carb)

Eagle Mike sells a kit. http://www.eaglemike.com/Air-injecti...ff-kit-AIS.htm (EDIT: this is for a Gen 2 head on a Gen 1)


My guess is that it was run out of oil and you probably need to do more than just the head. Likely a 685 kit. Contact Eagle Mike and I'm sure he'll give you a good idea of what you would be looking at.

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

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Last edited by klr4evr; 02-28-2014 at 09:24 PM. Reason: I screwed up.
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post #3 of 7 Old 02-28-2014, 09:18 PM
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Holy crap Batman. I'm getting dyslexic in my old age. Thanks for picking that up.

I meant to say that you need to plug the AIS connection at the carb if using a Gen 1 head on a Gen 2.

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

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #4 of 7 Old 03-01-2014, 07:14 AM Thread Starter
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Quote:
Originally Posted by klr4evr View Post


My guess is that it was run out of oil and you probably need to do more than just the head.
That is an unknown but apparently not all that uncommon to find the cam bearings scored, even a head like that on ebay.
I have dreamed up an idea how to repair the head if I can find someone who can do it. Same way as you would resize a connecting rod by cutting the cap down and reboring the hole.
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post #5 of 7 Old 03-01-2014, 08:29 AM
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Read on another forum; outfit in CA (Petaluma?) rehabs heads; new line bore and bronze cam bearings included; about $ 500 if I'm not mistaken . . .
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post #6 of 7 Old 03-01-2014, 08:45 AM
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http://www.klrforum.com/showthread.php?t=30002

Fixing these heads could be quite lucrative with the demand for them!

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post #7 of 7 Old 03-01-2014, 09:21 AM
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Originally Posted by Damocles View Post
Read on another forum; outfit in CA (Petaluma?) rehabs heads; new line bore and bronze cam bearings included; about $ 500 if I'm not mistaken . . .
The thread mentioned is linked above; here's a link to the outfit that did the work:

http://www.enginedynamics.com/

Last edited by Damocles; 03-01-2014 at 09:24 AM.
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