Cam Shaft problem - Kawasaki KLR 650 Forum
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post #1 of 6 Old 09-08-2014, 09:56 PM Thread Starter
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Cam Shaft problem

I have a 2011 KLR 650, bought new in March 2012. Over the last 2 summers I've only put on 4000km with regular specified maintenance.
Decided to take a road trip from Vancouver Island down the west coast to San Francisco. It was an epic ride!!! In addition, had a full tune up and oil change prior to leaving by a licensed mechanic. Bike literally rolled 4000KM at the start of the ride.

1825 km from home to San Francisco via US 101 and California 1 highways.

Leaving San Francisco decided to take US I 5 home to save time. Bike never went over 115km/hour. 260 km later just south of Corning, California my Cam Shaft literally snapped.

Stuck on the I 5 with a severely crippled machine. Now I'm thinking something this severe should NOT have happened to such a new bike with low KM's.

Has anyone heard of this or had this happen to them????? I have the pictures of the damage !!

Any thoughts????
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post #2 of 6 Old 09-08-2014, 10:03 PM
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Sorry for your trouble 12BMONEY! That really sucks. NEVER heard of a cam breaking in a KLR before.
Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #3 of 6 Old 09-08-2014, 10:36 PM
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What was your oil level at the time? Do you have warranty?

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 #4 of 6 Old 09-08-2014, 11:38 PM Thread Starter
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Oil level was good. I only had Factory warranty of 1 Year. My riding partner is a mechanic and some amazing people in California let us use there shop on there ranch. Had to order new cam shaft, cylinder head, compression springs etc... Engine was literally stripped down and everything inside was a nice shiny silver, except for the cylinder head. Crazy photos of all the damaged parts.
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post #5 of 6 Old 09-08-2014, 11:46 PM
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Hi 12BMONEY!
Sent you a pm with my email address. I will post the pics if you want as you won't be able to till you have 15 posts on the site.
Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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post #6 of 6 Old 09-09-2014, 05:02 AM
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WHICH camshaft "snapped," 12BMONEY? Intake? Exhaust?

And, where did the break occur on the camshaft?

Haven't heard of a camshaft fracturing on a KLR650; have seen and documented in pictures a Generation 2 with grenaded KACR (Kawasaki Automatic Compression Release) on exhaust cam, scored exhaust cam caps, scored exhaust cam journal (ruining cylinder head), grenaded valve cover; probable cause: Oil starvation. But, neither camshaft "snapped" in this case, although the exhaust cam required replacement.

Looking forward to your response and pictures posted through the courtesy of justjeff. E-mail the image files to him, and he will post 'em for all to see.

Too bad your otherwise splendid ride was compromised by this surprising malfunction/failure; glad you're back on the road.
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