2008-2009 oil burning problem - Kawasaki KLR 650 Forum
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post #1 of 4 Old 10-05-2014, 09:16 AM Thread Starter
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Join Date: Oct 2014
Location: Joisey, southern half
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2008-2009 oil burning problem

As stated above, it seems that those years are prone to oil usage. My question is why? Bad piston design? Pistons fitted to loose in the bore? Tapered bores from the factory? Poor oil return to the crankcase?

My main concern is whether or not this oil problem can be cured with a replacement piston or cylinder?

Thanks all for your help in answering my questions. There is a few bikes in that year spread for sale that I would consider buying if the problem is fixable. I don't want to end up
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post #2 of 4 Old 10-05-2014, 12:18 PM
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Location: Alberta, Canada
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Yup, those years do seem the most prone to being oil burners. Though that's not the case in all of them, I have an 08 and it only uses a little oil when I bag the heck out of it. If I keep my RPM below 5000 it doesn't use any. All years can be oil burners though, I've heard of Gen 1's doing it and also the late models.

That being said, one of the overbore kits and a new piston will cure the problem permanently. The 685 kit has been around for a long time and seems to do the trick well. The kit is reasonably priced and you just have to take the cylinder in to get it bored oversize.

The big thing is to remember to keep an eye on the oil level regardless of what year you choose. If you do have one that uses oil and it runs too low it will toast the head in pretty short order... Big $$$!

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post #3 of 4 Old 10-05-2014, 08:40 PM
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Piston and rings re-designed for 2008 models; low ring pressure; many "pumped oil." Some did not.

Re-re-designed during the 2009 model year (I think); don't hear much about excessive oil consumption any more.

Generation 1 pistons and rings now unavailable from Kawasaki; must retrofit to newest design.

Good history on "KLR650 Only" thread on "Thumpers" forum; Adventure Rider website.
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post #4 of 4 Old 10-08-2014, 07:26 PM
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I used to be anal about my vehicles if something wasn't right. Anymore, as far oil is concerned, I check it and if it needs it before the scheduled change I just add and be done with it.

2007 KLR 650
1997 Suzuki RMX 250
1996 Yamaha WR 250
1983 Yamaha IT 175
1976 Kawasaki KD 175

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