1990 KLR Tengai Resto-mod.... Maybe - Page 2 - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

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post #11 of 108 Old 12-30-2019, 09:34 AM
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Originally Posted by ironranger88 View Post
Next question While I'm working these transmissions and replacing cranks.

Both of these pistons look good, but I'm assuming a honing and some new rings would be in good order... Doesn't look like I can find anything easily. What is recommended for piston kits without getting into all of these silly "big bore" kits and such.
Doesn't anyone sell just a simple set of OEM rings?
No, they don't. Kawasaki usta sell a standard ring set and .5 and 1mm over ring sets. No longer available. Someone once claimed that they had found a ring set that could be used in place of the OEM, but it was vaporware.

You say that the bore and piston look good. I will be branded as an Astro-van mechanic of the worst order for saying this, but consider cleaning things up and running it. All you have to lose is some time and a head and base gasket. Your alternative is to spend a few hundred on a big-bore kit. If you put it together and it is horrible and depressing, take it back apart and put a 685 in it. Of course, use your best shade-tree mechanic practices to ensure cleanliness and proper fitment during this dangerous, foolish, and ill-advised activity.
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“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

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post #12 of 108 Old 12-30-2019, 10:30 AM Thread Starter
2nd Gear
 
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No, they don't. Kawasaki usta sell a standard ring set and .5 and 1mm over ring sets. No longer available. Someone once claimed that they had found a ring set that could be used in place of the OEM, but it was vaporware.

You say that the bore and piston look good. I will be branded as an Astro-van mechanic of the worst order for saying this, but consider cleaning things up and running it. All you have to lose is some time and a head and base gasket. Your alternative is to spend a few hundred on a big-bore kit. If you put it together and it is horrible and depressing, take it back apart and put a 685 in it. Of course, use your best shade-tree mechanic practices to ensure cleanliness and proper fitment during this dangerous, foolish, and ill-advised activity.
Great Info. Thank you!

After Letting the CA engine oil soak last night, I'm able to smoothly transition though 1-3 gears, but it SOLIDLY sticks and does not want to do into 4th. I'll keep working at it.

There is a "Smidge" of surface discoloration inside as if it COULD have started to rust in some areas... But I'm in agreement with you. I'm probably going to go with the "easy" route first.

IF I can get this thing to go into 4th on the table, I'll just button it up with the original piston and rings (AS IS) and just enjoy it for a while. Unfortunately only got 80psi out of the compression test before removal of the top end, but Im Chalking that up to the Kacr doing it's job. I'll to the tube hold open thing later.

Any suggestions on getting this beast into 4th? (I have the inner clutch basket on its shaft, spinning it counter clockwise while working the shifter)
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post #13 of 108 Old 12-30-2019, 11:40 AM
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You might as well pull the clutch cover off so that you can verify the 92081 spring is in good shape and that the 13145 cam and 13165 pawl (there's your Sturmey-Archer part) is working correctly. You'll be able to see if the external shift mechanism is working right. Anything more than that will require splitting the cases.

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #14 of 108 Old 12-30-2019, 11:44 AM Thread Starter
2nd Gear
 
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You might as well pull the clutch cover off so that you can verify the 92081 spring is in good shape and that the 13145 cam and 13165 pawl (there's your Sturmey-Archer part) is working correctly. You'll be able to see if the external shift mechanism is working right. Anything more than that will require splitting the cases.
Yeah, Kinda hoping it'll just start working...
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post #15 of 108 Old 12-30-2019, 11:52 AM
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I assume you are loading the input shaft and trying to shift it. Try loading the output shaft and trying to shift it. Sometimes applying the force form a different direction on the drum can help.

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #16 of 108 Old 12-30-2019, 01:39 PM Thread Starter
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I assume you are loading the input shaft and trying to shift it. Try loading the output shaft and trying to shift it. Sometimes applying the force form a different direction on the drum can help.
Tried Loading the Sprocket shaft and ACTUALLY got it go! ONCE, then I couldn't get it back out. lol After a few love taps on some things, it loosened it and got it back to 3 gears. lol So I decided to crack the case...

I'LL GIVE YOU ONE GUESS AS TO WHAT WAS THE FIRST THING THAT FELL OUT!

Haha...

What are the chances that I'd buy a bike with a bad crank, then an engine with a bad Transmission. This will work! haha Eventually, with a lot of work.
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post #17 of 108 Old 12-30-2019, 03:17 PM
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Originally Posted by ironranger88 View Post
Tried Loading the Sprocket shaft and ACTUALLY got it go! ONCE, then I couldn't get it back out. lol After a few love taps on some things, it loosened it and got it back to 3 gears. lol So I decided to crack the case...

I'LL GIVE YOU ONE GUESS AS TO WHAT WAS THE FIRST THING THAT FELL OUT!

Haha...

What are the chances that I'd buy a bike with a bad crank, then an engine with a bad Transmission. This will work! haha Eventually, with a lot of work.
Exactly which gear is that & on which shaft?

Western Power Sports sells PROX piston kits. Standard size only for the KLR650, Fits All Years regardless of what the book suggests.
Part #19-4687 / $165.63 msrp

Wossner also sells 2 near standard bore size KLR650 piston kits, albeit 11:1 compression ratio.

If your bore is not too out of round or tapered. Just a light glaze breaking hone & clean with scouring powder.

I've got ZERO personal experience with those 3 pistons.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #18 of 108 Old 12-30-2019, 04:00 PM
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https://youtu.be/Qkuu0Lwb5EM

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
Tom Schmitz is online now  
post #19 of 108 Old 12-30-2019, 06:50 PM Thread Starter
2nd Gear
 
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Nice...
lol
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post #20 of 108 Old 12-30-2019, 06:56 PM Thread Starter
2nd Gear
 
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Originally Posted by pdwestman View Post
Exactly which gear is that & on which shaft?

Western Power Sports sells PROX piston kits. Standard size only for the KLR650, Fits All Years regardless of what the book suggests.
Part #19-4687 / $165.63 msrp

Wossner also sells 2 near standard bore size KLR650 piston kits, albeit 11:1 compression ratio.

If your bore is not too out of round or tapered. Just a light glaze breaking hone & clean with scouring powder.

I've got ZERO personal experience with those 3 pistons.
Was hoping to just hone and use standard rings... But it sounds like a whole new piston is all I can do. So, yea, I'm just going to throw the old one back on and go for broke. (for now.)

I have no Idea which gear that was, but it's on the input shaft. If You know anyone in need of a Transmission with a Vegas dog (broke and busted)... I might know where they can get one cheap! lol
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