Oil burning near exhaust manifold and overheating - Kawasaki KLR 650 Forum
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post #1 of 4 Old 05-13-2020, 06:07 AM Thread Starter
Join Date: May 2020
Posts: 1
Oil burning near exhaust manifold and overheating

Hey guys,

It’s my first post here. I have a second hand 2008 klr650 with 50k on the clock.

Ive started having overheating problems so I decided to start troubleshooting. First I checked the fan motor. That works.

Did something similar to this. Using a paper clip and connected the ends then switched the ignition on. It began to spin.


Then I checked the thermostat. That works but at a high temp close 100•c. Seems to high. Boiled in a pan and watched open but water was close to boiling when opened.

Pump not working. Used this guys method and no moving water.


So now im pretty sure I have to replace parts of the water pump.

When performing the tests I noticed smoke coming from where the exhaust is bolted to the block. (Can take pictures if needed.) There’s also oil leaki around the join. I think it’s the oil which is burning and causing the problem.

Any idea what’s going on? Why is the oil coming from? Why is it leak/burning around the manifold?

Thanks guys

Shak is offline  
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post #2 of 4 Old 05-13-2020, 11:37 AM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,500
If your bike has the extra hose clamps on a fitting in the middle of the lower radiator hose like the Gen 1 bike in the 1st video (40-45 second mark) then it has probably been fitted with a Thermo-Bob radiator by-pass to warm the engine quicker & more completely & that is a GOOD Thing. And yes the Thermo-Bob thermostat will be at least 90C and the temperature gauge will normally be near mid-gauge, with a properly operating thermostat.

The cooling fan switch is at the bottom of the radiator & it will normally turn ON when the Gen 2 gauge gets to about 5/8 -3/4 of temp gauge scale. And this fan switch temperature is irregardless of Thermo-Bob or standard system. The fan usually does not have to run except sitting in traffic or long steep climbs in 1st & 2nd gear.

With the hoses disconnected from the pump cover, if you can see the impeller turning when you touch the starter button, it should pump. UNLESS someone has had the cover & impeller off before you and either left its mounting nut loose or worse stripped the threads on the shaft.
One won't see coolant movement thru the radiator cap area until the thermostat Opens at least part way!

In the second video there is now way that can work to check the coolant pump. IT can't retain Prime.
The rear hose and bucket need to be elevated to footpeg height. The end of the rear hose needs to be held UP until the forward hose which needs to be held near handlebar height & filled with water until one starts to see the water flowing out of the inlet hose and into the bucket. This type of pump can't purge an air bubble. Keep the forward hose elevated. Then start the engine.

Be certain that the lower hose from the radiator connects to the REAR nipple on the coolant pump. The Forward nipple from pump goes the base of engine cylinder.

As to the oil leak drooling onto the exhaust, you need to remove the fuel tank. Degrease & dry the area if still uncertain of location of leakage. Spray gray or white foot powder on area & let dry. Then start bike, the powder will stain quickly.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #3 of 4 Old 05-13-2020, 12:23 PM
2nd Gear
Join Date: Apr 2019
Location: Minnesota
Posts: 135
As to the burning at or near the exhaust port. You may have a leaking exhaust gasket. Check the torque of the acorn nuts holding the header to the engine. Values are in the manual. You may have a leaking valve cover gasket as well but that should be very easy to see and smell burning oil.
pdwestman gives very informed advice. He owns a Kawasaki dealership.
Uncle Dick is offline  
post #4 of 4 Old 05-13-2020, 03:48 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,500
Originally Posted by Uncle Dick View Post
He owns a Kawasaki dealership.
Correction, Used to own a Kawasaki dealership. Independent repair since August 2016.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
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