Africa zigzag KLR 2007 guzzling oil in Sudan - Kawasaki KLR 650 Forum
Gadgets & Gizmos Discussion on the latest "toys" to enhance the adventure.

 2Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 22 Old 03-20-2018, 06:16 PM Thread Starter
Neutral
 
Join Date: Jan 2017
Posts: 9
Africa zigzag KLR 2007 guzzling oil in Sudan

Hey guys. I have been traveling around Africa for the past 11 months and 33 000 km on a KLR650 2007 along with 2 2009 KLR's.

My bike has been running perfectly until recently I noticed a substantial oil leak from the right side crank case cover. I checked the oil level and it did not seem damagingly low. However, since I repaired the leak my motorcycle has been eating through oil at an alarming rate-1 liter for 250km. With a slight ping in the engine when I open up at low revs.

I am currently in Khartoum in Sudan. I have a mechanic coming to assist with opening up the engine and assessing damage. I figured it could be piston rings (which I will edit from Toyota piston). Is there anything else I should look out for damage wise from possible oil deprivation or any suggestions that could assist in this endeavor?

Much obliged
Trouble is offline  
Sponsored Links
Advertisement
 
post #2 of 22 Old 03-20-2018, 06:24 PM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,449
Garage
Where, exactly, was the oil leak and how did you repair it?

How low was the oil when you repaired it?

Have you been diligent about cleaning the air filter, re-oiling it, and properly fitting it back in place? Assuming that you are riding many unpaved roads, this would need to be done almost weekly. Paved roads, every oil change/5000KM.

Answers will help with diagnosis.

The mechanic should pull the right side exhaust cam cap and inspect for damage. If no damage, the head is good.

A possible cause is a dusted piston, the noise being piston slap. If so, a new piston, rings, and cylinder hone are required. If the piston ring lands are not broken, less rigorous fixes could get you going until proper repairs can be done.

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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


Sting like a butterfly.

Last edited by Tom Schmitz; 03-20-2018 at 06:29 PM.
Tom Schmitz is offline  
post #3 of 22 Old 03-20-2018, 11:37 PM Thread Starter
Neutral
 
Join Date: Jan 2017
Posts: 9
Hey Tom we are generally diligent with the cleaning of the air filter but on that occasion it had been about 2-3 weeks without a good clean with some desert sand etc. but the filter did not look overly bad when cleaned. Fitted properly. Oil looked black with a low viscosity. Serviced every 5000-5500 km and needs the 40 000 km service now.

I believe the oil leak occurred when I over filled the oil on the first service of the trip. But only about 4000 km ago she started sweating oil from the gasket around the crank case cover (front). Due to not having the correct seals to remove the crank case cover I used gasket maker to seal the area, with 100% success so far. No leak.

The small ping on acceleration has been happening for +\-1000 km but I thought it could be a carbon build up.
Trouble is offline  
 
post #4 of 22 Old 03-21-2018, 11:01 AM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,449
Garage
Khartoum is a fairly modern city; I hope you have access to a head and base gasket and engine refurbishing services. That amount of oil consumption is alarming if it is not an external leak.

These air filters rely on oil in the filter to catch dust. Without sufficient oil worked into them they can not filter properly. It doesn't take much sand to dust a piston, and that destroys the rings' ability to control the oil on the cylinder wall. Pistons in engines that burn oil are usually very clean on the top of the piston. The burning oil tends to clean carbon off, so there would not be a carbon build up to cause pre-ignition and pinging or knocking. A pinging or knocking sound on a dusted piston is likely to be piston slap, as the piston is not running up and down smoothly, but rather rocking back and forth in the cylinder. The skirt is hitting the cylinder every time it reverses direction.

Unfortunately, the only way to check is to remove the head and cylinder to get a look at the piston.

Here is what a dusted piston looks like.


This one was pretty bad, burning a liter in several hundred kilometers. It had a loud piston slap, too.

The only fix, obviously, is a new piston, rings, and cylinder bore.

The other problem is the head. If it was run low on oil, to the point where there was no oil for the pick-up tube to stay submerged, and the head was starved of oil the first thing to go is the right-hand exhaust cam journal. Checking that will tell you if the head is ruined.

How much further do you have to go on your trip, what resources do you have for repairs and how good is your mechanic?
DPelletier likes this.

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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


Sting like a butterfly.
Tom Schmitz is offline  
post #5 of 22 Old 03-21-2018, 11:31 AM Thread Starter
Neutral
 
Join Date: Jan 2017
Posts: 9
Piston is broken. Bike in bits. Had a pretty big carbon build up ontop of the piston... What will I see if I see the right exhaust cam journal to diagnose complete ruin.

I have no gaskets available the mechanic stripped the whole engine while I was out. He Is going to search for another 50 piston tomorrow. This is a real African bush job going on 🙈🙈🙈 but mechanic comes highly recommended.
Trouble is offline  
post #6 of 22 Old 03-21-2018, 12:03 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,338
I had a comment 90% written, got interrupted and lost it all.

I dislike reading simply that one cleaned or cleans their KLR air filter on a regular basis or an irregular basis.
I'm more concerned about how one Re-Oils the freshly cleaned air filter, with exactly what oil on what brand & style of air filter and how much oil is used.
If the air filter has been properly maintained, one ought to check the underside of the clean air box, ahead of the air filter for heat damage/melting (burnt hole from exhaust leak). As seen here,

Melted Reservoir, Dogs! (Airbox, too)



If the upper or middle ring land of the piston is what is broken it may have been caused by detonation caused by old/low octane fuel.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
pdwestman is offline  
post #7 of 22 Old 03-21-2018, 12:17 PM Thread Starter
Neutral
 
Join Date: Jan 2017
Posts: 9
I used the oil that I used for the bike to oil the air filter generally 15w-40 then squeeze it. But it looks like this is oil depravation, 8000 km from home in a country with no Kawasaki's.
Trouble is offline  
post #8 of 22 Old 03-21-2018, 12:24 PM
3rd Gear
 
dan filipi's Avatar
 
Join Date: Feb 2017
Location: Van Nuys Cali
Posts: 605
Garage
I had a question, not to hijack....what are the telltale signs a PROPERLY OILED air filter is trapping all the dust? I ask because it can be a bit tricky for me sometimes to know for certain the filter medium is in good contact with the air box all the way around it, especially since the center screw has a stop lip on it to prevent over-tightening. My filter seems loose against the air box. I should grease that edge.
The clean air side of the plenum and carb throat look clean as best I can tell by shining flashlight in thru the screen, but is that a good enough judge?

2016 KLR 650
2017 BMW S1000RR (traded in for
2018 Ducati V4S
1983 GL1100 Goldwing
2017 Yamaha R1
dan filipi is online now  
post #9 of 22 Old 03-21-2018, 01:04 PM
4th Gear
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,268
too late to say I suspect a broken ring and/or piston ring land....good luck with the repair.

Cheers,
Dave
DPelletier is offline  
post #10 of 22 Old 03-21-2018, 01:16 PM
4th Gear
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,268
Quote:
Originally Posted by dan filipi View Post
I had a question, not to hijack....what are the telltale signs a PROPERLY OILED air filter is trapping all the dust? I ask because it can be a bit tricky for me sometimes to know for certain the filter medium is in good contact with the air box all the way around it, especially since the center screw has a stop lip on it to prevent over-tightening. My filter seems loose against the air box. I should grease that edge.
The clean air side of the plenum and carb throat look clean as best I can tell by shining flashlight in thru the screen, but is that a good enough judge?
I use white grease on the filter lip; it helps with the seal and it's easy to check and see if any dirt was getting past.
As far as making sure it's seated, I wiggle the filter and cage assy several times during the tightening of the bolt to make sure it's seated in place.


2 cents,
Dave
DPelletier is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Issue with 2007 KLR MedServ60Driver 1987 to 2007 Wrenching & Mods 4 01-19-2016 10:27 AM
New KLR owner - Johannesburg, South Africa Neil650 Introductions 1 05-13-2015 03:33 PM
New to me 2007 klr 650 Mtgrizzlymn 1987 to 2007 Wrenching & Mods 14 10-01-2014 10:29 AM
New KLR owner from South Africa Evil Eric Introductions 10 01-11-2010 01:51 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome