Crankcase Swap - 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.

  • 2 Post By pdwestman
  • 2 Post By 650Stew
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post #1 of 4 Old 02-19-2017, 08:36 AM Thread Starter
Join Date: Feb 2017
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Crankcase Swap

All, great forum you guys have here. I have a 2009 KLR 650 that I'm fixing up. Left side crankcase was damaged when the previous owner rode it over something and busted the oil plug right out of the case. I'm assuming oil drained out rapidly and the motor suffered some extreme wear. No skid plate for some reason, get a skidplate!!

So, I have to replace that side of the crankcase and go through the motor to make sure all the components are sound. I found a case for a 2008 KLR 650, will they be interchangable?


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post #2 of 4 Old 02-19-2017, 01:05 PM
Join Date: Nov 2009
Location: Lander, Wyoming
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One must use a Crankcase SET. Not a Left half from one engine and a Right half from another. All of the bearing bores are "Line-Bored". As in the alignment dowels are in-place and the cases are securely bolted together, then boring begins, Perfectly Straight thru both sides.

Even a 1/2 a thousandth of mis-alignment between the 2 sides of a mis-matched case set would not be good.

2008 and 2009 are identical. Probably still the same cases, other than paint color thru 2017.
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Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 4 Old 02-19-2017, 02:32 PM
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Join Date: May 2014
Location: Texas
Posts: 1,260
Yes to pdwestman's comments.

If you happen to also use the 2008 left engine side cover, it will likely have the "deep hole" for one of the starter gear shaft bores. Easy to fix with just a 1/4" or so of rubber tube to fill the extra space.
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post #4 of 4 Old 02-19-2017, 02:37 PM
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I'd personally be inclined to look for a complete good used engine. By the time you rebuild the top end and replace the head (from running out of oil) and go to all the labor or replacing the cases, I think a used engine would be the cheaper and easier route to go. Just my opinion though
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