Coolant in Oil - Page 2 - 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 #11 of 17 Old 12-04-2018, 02:08 PM
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@Bill10 - did you get this problem sorted?

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 #12 of 17 Old 12-04-2018, 05:59 PM Thread Starter
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@Bill10 - did you get this problem sorted?
Yes, I only just got this part of the project wrapped a little over a week ago, but I had to get my dealer involved.

The head gasket replacement was uneventful, but the liquid in the crankcase persisted. When I got into the water pump, I found that the weep hole referred to a couple posts up was blocked off; whether on purpose or crud got in there, I don't know. Also, I found that the flange of the outer "mechanical" seal had come apart from the rest of the seal; it's sort of a flange, spring and rubber seal in that order. I could see the replacement is a single mechanical device so that wasn't right. Anyway, I made two attempts to replace the seals (inner and outer relative to the case cover) in the water pump. What a miserable process that inner seal replacement is! I damaged two inner seals...or so I thought....and decided it was time for the pros. Once in my dealer's shop, they reported that the impeller shaft was bent and needed replacement. Did I do that in the process of being in the case twice? Dunno. Anyway, they replaced the shaft and properly rebuilt the water pump. Not too bad on the pocket book...a little over $300. Working okay now.

So, over the last week I've been working on getting the bike ready for the season ending local rally here in Central Florida next Saturday and Sunday. Fresh Dunlop D606s, sprockets, chain and some other stuff. Replaced the crash guards, did some body work. Overall, I think I'm good...until the next thing that blows up on it.
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post #13 of 17 Old 12-04-2018, 07:30 PM
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Aye, removing and installing those seals makes me nervous. I feel that I have to get the flange seated fully and squarely, the o-ring is tiny, the case seems fragile, the stud on the shaft is fragile, yeesh. Gives me the willies when I have to do it.

I'm glad to hear you got it sorted and I hope you enjoy the rally.

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post #14 of 17 Old 12-05-2018, 07:15 PM
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Bill10, Glad that your KLR is back on the roads. Your dealer was very gentle, as I'm sure you will agree.

Be glad that you didn't have to replace a water pump shaft or Alternator Stator on a Kawasaki Teryx 4. I recently had 20 bags of nuts, bolts, screws & plastic re-usable rivets attached to 20 major interior passenger compartment seats, plastic covers, skid plates, engine covers and such to replace a burned stator winding.

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post #15 of 17 Old 12-05-2018, 08:39 PM
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Bill10, Glad that your KLR is back on the roads. Your dealer was very gentle, as I'm sure you will agree.

Be glad that you didn't have to replace a water pump shaft or Alternator Stator on a Kawasaki Teryx 4. I recently had 20 bags of nuts, bolts, screws & plastic re-usable rivets attached to 20 major interior passenger compartment seats, plastic covers, skid plates, engine covers and such to replace a burned stator winding.
Never worked on a Teryx, but I was in pretty deep doing the clutch on my LT. My wife walked into the garage one day and proclaimed that we would never ride that motorcycle again. Thankfully, she was wrong.
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post #16 of 17 Old 12-07-2018, 06:41 AM Thread Starter
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I also have a UTV...Arctic Cat HDX500. Everything is so boxed in even the most rudimentary service procedures either require contortionist skills to do (e.g. checking the oil) or take hours of disassembly and assembly time just to get to whatever needs adjustment/replacement (e.g. replacing the oil filter).
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post #17 of 17 Old 12-07-2018, 09:55 AM
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I also have a UTV...Arctic Cat HDX500. Everything is so boxed in even the most rudimentary service procedures either require contortionist skills to do (e.g. checking the oil) or take hours of disassembly and assembly time just to get to whatever needs adjustment/replacement (e.g. replacing the oil filter).
And low population states like WY, MT, SD, ND, UT, ID often encourage license plating of the ATV's / UTV's to help bolster the state road maintenance budgets so people can use their off highway units on state & county highways & city streets like having a second car.

Problem is, they are not a car! They are a light weight sporting vehicle, with the maintenance requirements of a race car / race truck / swampbuggy / dirt bike!

As you pointed out, maintenance access is often pitiful, therefore labor intensive and often neglected by the owners. And then the neglectful owners whine and complain about the cost of maintenance/repairs. Air filter service possibly every week in dusty areas. Oil & filter changes of 3-5 times as often as a car. Off-road capable tires wear out in 3000-5000 miles vs 30,000-50,000 miles and cost just as much, if not More.
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