Join Date: Nov 2009
Location: Lander, Wyoming
chrider, I might suggest that you remove the valve cover and inspect the camshaft bearings for wear and clearance with Plasti-Gage.
You might consider installing KLX650 banjo bolts #92150-1641 or drilling 2, 1/8th inch holes thru the existing banjo bolts of the oil delivery pipe if bearing surfaces or Plasti-Gage shows some wear.
I don't think any company makes Aluminum driven clutch plates for a KLR, do they? What can you tell us about your engine balancer chain & the adjuster, aka the doo-hickey? Balancer chain rubbing the engine case could also explain the Aluminum ppm.
Modify at "YOUR OWN RISK"!
Still riding my 1987 KL650-A1. 85,000+ miles & counting