Stroking the 650...? - Kawasaki KLR 650 Forum
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post #1 of 18 Old 09-22-2012, 07:01 PM Thread Starter
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Stroking the 650...?

Has anyone here thought about this for our motors? I have a second crank here to play with and it has me thinking......anyone?

I am going up to a 705 and while it's apart I was thinking......if possible, why not??? I remember seeing it advertised for roughly $350..... That should get it close to the 733 if I recall correctly....interesting....lol.

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post #2 of 18 Old 09-23-2012, 05:29 AM
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I understand the throw on the crank would need to be increased but what about the availability of modified rods and or pistons to accomplish stroking this motor. And, is the liner long enough for the additional stroke?
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post #3 of 18 Old 09-23-2012, 06:44 AM Thread Starter
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I know it's been done already to a 705 and is running strong......it's just a matter of.....pulling the pin and doing it I guess......?

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post #4 of 18 Old 09-26-2012, 09:44 AM
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Originally Posted by willys View Post
Has anyone here thought about this for our motors? I have a second crank here to play with and it has me thinking......anyone?

I am going up to a 705 and while it's apart I was thinking......if possible, why not??? I remember seeing it advertised for roughly $350..... That should get it close to the 733 if I recall correctly....interesting....lol.
I wish someone were still around...


I was just thinking about this the other day

If there were a tested means and availability I would stroke it in a heartbeat

My 685 will likely become a 705 a bit down the road
A stroked 705.......sounds about right
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post #5 of 18 Old 09-26-2012, 11:23 AM Thread Starter
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I agree with that, speed, also, There was one man who was the top of the game when dealing with the workings of our engines and unfortunatley no-one has come remotely close to him from what I can see. It is a shame for sure both his passing and the inability of anyone to get anywhere near where he left off at. Sure a few of us have stepped up and done most of what he had already done or talked about...but we are still like newborns flopping around grasping at anything trying to see what works and what doesn't. He was light years ahead of any of us...imho.

I finally went to get my new 705 cylinder yesterday from my machinist and asked him what he thought about it. The stroking that is. He asked from what cc to what cc and explained all of the steps to get it there. I started to doubt if it is really worth all of the work....? As bad as that is to admit...I'm a firm believer in modifications just for the sake of doing them. Even better for more power. But even I have a line to cross on this one.
Sending it out to get stroked, a different length connecting rod, a different piston(I like these Cary pistons!) They have served me very well.
There is so much to be done and to change to keep me so interested in it. I just don't know yet....?

What have you thought about this and what it takes to get the job done?

I am still going after the timing and finding 5 degrees of advance mechanically.

And not 100% sold on my first thought of adding weight to the counter ballancers either. I thought I had that one semi figured out too....that is still up in the air....?

What are your thoughts....and that goes out to anyone.....?

Willys
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post #6 of 18 Old 09-26-2012, 01:44 PM
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Gad. How would you do it? Here's a table for talking purposes:



I think I'd be tempted to start with a 685 piston, as it requires no changes to the cylinder liner.

Now, if you're going to get the stroke by grinding the crank undersized and offset, then you're very limited as to how much stroke you can get. I would think if you went much over 1.2 mm of stroke that you'd need a new rod anyway as you'd need WAY undersized bearings. That doesn't seem like a good idea, as you only get to a 705.

If you can't get it by grinding the journal, then you need to build a new crank. You might be able to do a good weld job.

Since the engine is a DOHC you might be able to go long and bring it up to 805. That's welding in 6mm of crank throw. Decking the cylinder up 6mm doesn't seem unreasonable with a base spacer and two gaskets. I'm out of my element, not knowing how much you can weld up a journal. Is 6mm out of the question?

My gut feel is that a stroker is beyond the point of diminishing returns. I almost think that dropping in an old Honda 500/550 or Yamaha 650 twin would be a better way to go and afford more downstream tuning opportunities. Those are making 50hp stock, with torque similar to the KLR.

Dunno if they'd fit though. Screw it; put a 600 Ninja in there.

T

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post #7 of 18 Old 09-26-2012, 01:58 PM
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There's a boo-boo in my table at the 805 displacement.

Should be this:

102.53 97.54 805 14.54 7.3


T

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post #8 of 18 Old 09-26-2012, 03:25 PM Thread Starter
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You are already way above my understanding of the process to getting the stroke accomplished.....it is something I haven't even read much about I admit. I was just told by my machinist that it would be conciderable work for little gains. I am already going to be at the 705cc range as of next spring, with a fully modded engine, well as far as I can get lets say. The next step would have been stroking it.
I have to agree with you and my guy, that it may just be too much to take on.
I would love to talk to the guy who I heard has already done this and see what his feelings are if he would go to this length if he were to do it over.....oh the joys of leaving a site ....lol....at least I think it was there or the world where this guy hangs out at.

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post #9 of 18 Old 09-26-2012, 05:39 PM
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I think Tom is on the right path with a twin cylinder.

I used to work in a machine shop and welding cranks was one of my duties. Does it work? Yes, however the stresses upon the crank are unbelieveble.

If I remember corectly there was a fella on one of the other sites (ADV) that was undertaking the task of loading a twin cylinder into the KLR frame. Maybe it was a 650 Ninja motor I am just not sure.

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post #10 of 18 Old 09-26-2012, 05:52 PM Thread Starter
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I've seen two seperate people do it so far with success, one much better than the other, and with different engines. It would be the easiest way to quickly get the horsepower we seek....BUT...it will never be a KLR again. That is why I haven't gone that route already. The money I have tied up in my bike is embarrassing! I could easily have bought the Bemer for less at this point....but still wouldn't be what I wanted, a simple easy to fix and maintain machine. Even after all of this crap I have done it's still basically a KLR, fixed with a rock and some bubblegum!
So I stay with what I know and find other ideas to get even more......augh...please help me!!!!

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