Kawasaki KLR 650 Forum - Reply to Topic
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

Thread: Wossner pistons vs oil burning Reply to Thread
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  Topic Review (Newest First)
05-17-2013 10:04 PM
willys Now that is excellent news and great work my friend......keep diging up the dirt on mother Kawi and her dirty little secrets.
05-17-2013 07:44 PM
pdwestman Just to let more people know, Kawasaki CHANGED the PISTON, RINGS and PISTON PIN, on the 2012 and UP models, mostly silently, of course.
Hopefully for the better, less oil issues maybe, time will tell.

I can ONLY GUESS, that maybe the PISTON PIN is possibly shorter. To make the weight of the pin and piston assembly LIGHTER, maybe.

ALL years from 1988-2013, use the same rod kit, so the pin diameter is the same.
So, it looks to me like one could use 2012 and up OEM piston, rings and pin in all the OLDER KLR650's, with hopefully better results than the 2008-2011 OEM parts. Available in STD, +.020" (+.50mm) or +.040" (+1.00mm) sizes. I personally, ALWAYS replace the pin anyways.

To the OP, NONE of the NEWER ring sets fit our OLD PISTONS!
pdwestman
05-09-2013 09:34 AM
Tom Schmitz willys -

My first thought was that it was probably a business decision, going with one company's products.

But then, perhaps there weren't 'only two' that went bad ;^).

T
05-09-2013 07:43 AM
willys Tom you are correct! I stand corrected.....It looks like he has for some strange reason dropped all kits made with Arris pistons, wonder why? He has all of his kits now with the much superior pistons made by JE. Plus he doesn't offer the 688 kit from what I could find. I wonder why? If they only supposedly had 2 go bad....? But that wasn't the fault of the pistons but from the installation from what they said......but hey that is past history and I shouldn't have brought it up....sorry.

It just makes me wonder though why he has opted to switch to the well known and proven piston company JE which has been supplying the 685 and 705 pistons for years. I can't wait for someone to tell us what the big kit feels like.....I'm sure they are now at the limits of the sleeve and the cooling capabilities of this engine in it's stock form.

All interesting news.....great to see someone going after the power once again.
05-09-2013 04:20 AM
Ol dirty bike
Quote:
Originally Posted by Damocles View Post
Why not oversize Kawasaki pistons and corresponding ring sets?

In the bad old days, rebores and installation of oversize pistons and rings were common steps in engine rebuilding.

I think Kawasaki catalogs two oversize replacement piston kits.
I do have this option available, I can get 1mm oversize OE piston but when I add the ring cost it will be as much as the Wossner option. Also I'm loathed to replace with OE after reading all the threads on this forum as it seems quite likely a "weak spot". Measuring the bore shows no significant wear so my thoughts are a hone to freshen it up + Wossner piston (which come in 0.01mm) oversize options
05-08-2013 09:52 AM
Damocles
Quote:
Originally Posted by willys View Post
Do you really want a known problem ring set in your bike after suffering this problem already?
So, ALL Generation 2 KLR650s have the "known problem ring set," willys?

The problems surfacing with some 2008 models still persist, to this day?

You're CERTAIN? The production years, 2008 through 2013 inclusive, universally involve "problem" rings?

I do not expect an answer, but . . . what is your source of this critical information?

Member-wise, how many Generation 2 KLR650 owners on this forum have experienced the "known problems" of defective design/manufacture/material piston rings?
05-08-2013 09:47 AM
Tom Schmitz willys -

All of the kits that Mike sells right now use JE pistons. I think it was only the 688 that used Arias.

T
05-08-2013 09:35 AM
willys If you use Kawi piston and rings you get the rings they are installing in the new bikes now as all old stock gen I piston and rings have been used up. Do you really want a known problem ring set in your bike after suffering this problem already? The EM kits aren't JE pisrons either unless he has changed piston manufacturers. They are Aeris or however you spell it pistons......it's the Shnitz kits that use JE pistons.
It's a personal choice
05-08-2013 09:30 AM
Damocles Why not oversize Kawasaki pistons and corresponding ring sets?

In the bad old days, rebores and installation of oversize pistons and rings were common steps in engine rebuilding.

I think Kawasaki catalogs two oversize replacement piston kits.
05-08-2013 09:16 AM
Spec
Quote:
Originally Posted by Ol dirty bike View Post
Hi I have recently become the proud owner and rider of a 1990 (ish) Tengai, which for the most part is very enjoyable! however the subject of oil consumtion has raised its quite consideable head! Initial thoughts of smoke on start up led me to replace valve seals with no difference noticed. Then as I read up on the subject a little more I found this forum and the many pages and theories around the piston and rings! Unfortunatley it seems the 685 big bore will not work with the liner on a bike of this age, so the other option is a replacement Wossner piston. Has anybody any experience with these on the 650 engine? Will this help my impressive 1 liter of oil in 200 miles being burned?

Welcome to the forum!

My guess is that the oil ring is broken or a very worn cylinder. It's an iron liner so you can bore it oversize.

A good machine shop can probably find something cheaper than the Wossner. Hey it's a KLR afterall!
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