campfire's left side rework - 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 21 Old 09-24-2017, 02:55 PM Thread Starter
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campfire's left side rework

An absolute perfect day for riding here in northern California.....

And I'm stuck in the garage staring at this....


Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California

Last edited by Tom Schmitz; 09-25-2017 at 03:22 PM.
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post #2 of 21 Old 09-24-2017, 07:50 PM
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campfire, What are you doing in there?

pdwestman
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post #3 of 21 Old 09-25-2017, 12:05 AM Thread Starter
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A photo you took today

Quote:
Originally Posted by pdwestman View Post
campfire, What are you doing in there?


Well..............................

A funny thing happened on my ride to Iowa. But I made it back after 4,000+ miles and had a noise start somewhere in the Texas panhandle.



(Fast forward to last week)



Went to adjust the valves, exhaust were TIGHT, pulled the cams, dropped the chain guide bolt down into the side case, found the exhaust valves leaking, pulled the side case, found the bolt, and the broken Doo spring, saw the damaged timing chain guides while I was in there, pulled the head to get the guides out, saw the marks in the cylinder wall, pulled the cylinder off to find the 688 piston burned and scored...



Ordered all the parts including a new EM 685 kit, head's getting a valve job, replacing the timing chain with guides & the balancer chain while I'm in there.



So I'm off and running with the second engine rebuild.







This one should last longer than 18,000 miles, and I'm changing the oil every 1,800 miles now.






Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California

Last edited by campfire; 09-25-2017 at 12:14 AM.
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post #4 of 21 Old 09-25-2017, 12:28 PM
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campfire,
Double check your numbers. An EM JE685cc piston will be too small in a cylinder already bored for a WymanWinn Arias 688cc piston. May have go 692.

As to the broken EM Torsion Doo spring. You will need to re-drill the 1/16th inch hole to about 5:30-5:00 position. They possibly never should have been drilled at 7:00-7:30.

pdwestman
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post #5 of 21 Old 09-25-2017, 01:42 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
campfire,
Double check your numbers. An EM JE685cc piston will be too small in a cylinder already bored for a WymanWinn Arias 688cc piston. May have go 692.

As to the broken EM Torsion Doo spring. You will need to re-drill the 1/16th inch hole to about 5:30-5:00 position. They possibly never should have been drilled at 7:00-7:30.
Thanks for the heads up, but Mike is sending me an exchange cylinder. Mine will be turned into a 692 for someone else.

And I'm already working on re-drilling the hole. It was that "5:30 as it sits? or as the cover is on the bike?" thing. Then there are conflicting directions on different web sites, but getting the opposing ends at 180 degrees from each other seems to be the goal.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #6 of 21 Old 09-25-2017, 02:59 PM
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5:00-5:30 as the cover is installed on the bike.

I use 2 x 4 blocks to support the back-side gasket surfaces while on the drill press and a 1/4 inch shim at the top. This slightly tilts the Torsion spring towards the inner cover when the 90 degree stub is poked thru the 1/16th inch hole. Instead of relying on the groove in the EM doo to keep the Torsion spring from rubbing on the ring gear.

pdwestman
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post #7 of 21 Old 09-25-2017, 03:21 PM
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@campfire, you've got an interesting thing going on here. I'm moving it to its own thread for better visibility.

Tom [email protected]

I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

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post #8 of 21 Old 09-25-2017, 03:56 PM
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Any Ideas as to what / why the 688 piston burned & scored?

pdwestman
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post #9 of 21 Old 09-25-2017, 06:03 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
@campfire, you've got an interesting thing going on here. I'm moving it to its own thread for better visibility.
Thanks Tom!
Yeah, I thought of that when this started.

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Originally Posted by pdwestman View Post
Any Ideas as to what / why the 688 piston burned & scored?
Well now that's a very good question. I tried remembering back to all the engines I've worked on, and I asked around and had all kinds of stuff thrown out there. But in the end it was running when I tore it down, and was just noisy like a tractor should be after a long season. (I'm making myself feel better saying that)
Engine Dynamics over in Petaluma CA looked at it and said it looked like I ran it out of oil. (Like he's never seen that before with a KLR)
But after the rebuild, it never used oil and I was checking it at every fuel stop and it was full. I changed the oil before I left on my trip, and then changed it again in Guthrie Oklahoma after about 2,500 miles. It was right before that in Texas that the "noise" started.

So my conclusion is that it might have been thinned out oil which was definitely the case when I drained it. BUT... Michael did state that they have seen engine failure (premature wear) on KLR's that have been used for long highway hauls. I guess there's something to watch out for, running a lawnmower at 75 MPH for 300-400 miles a day. But Michael over there (great vintage British mechanic/machinist) did say that he was amazed about all the stories he hears where those KLR's go. "Ride the bloody things around the world, they do."







Also, when I pulled the timing chain out, the tensioner was almost at the end showing that the chain was stretched. And after 55,000 miles of good riding, I just figured to replace both chains while I was in there.
(and maybe, just maybe, use that as a selling point if I start looking at another ride with one more cylinder and another gear)

UPS just showed up with the second box of parts, but the wife wants to go over to the coast. So we're packing up the trailer and heading for Bodega Bay for a couple of days camping and I'll stop in Petaluma on the way home to pick up the head.
Maybe I'll have the new cylinder and piston waiting for me when we get back.

I'm hoping for some good fall riding when I get this back together.

Remember though................................ no matter what happens, what breaks, just keep it running so you can ride.

Get out there and ride. It's amazing where you can wind up.


Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #10 of 21 Old 09-25-2017, 06:07 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
5:00-5:30 as the cover is installed on the bike.

I use 2 x 4 blocks to support the back-side gasket surfaces while on the drill press and a 1/4 inch shim at the top. This slightly tilts the Torsion spring towards the inner cover when the 90 degree stub is poked thru the 1/16th inch hole. Instead of relying on the groove in the EM doo to keep the Torsion spring from rubbing on the ring gear.

Thanks! That's a great idea. I just got some new V-blocks for my drill press, maybe I can come up with a jig for the cover.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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