1990 KLR Tengai Resto-mod.... Maybe - 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 #1 of 108 Old 12-29-2019, 11:38 AM Thread Starter
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1990 KLR Tengai Resto-mod.... Maybe

Hey, I realized that I've been posting in the Introductin thread so far, So I thought I bring this project over to the area where it belongs!
Here is the link to where I've been so far. https://www.klrforum.com/introductio...brand-new.html

Update List:
1- I bought a 1990 KLR Tengai locally in Phoenix, AZ
2- It was run with VERY low oil which ceized the cams, Kacr exploded, Timing chain broke, and the timing gear on the crank "ruined" the teeth, so I decided to replace the engine.
3- found side fairings in London for a decent price, they're being shipped.
4- Speedometer "set up" was purchased from CA
5- New engine found in LA (possibly 35K miles)
6- Rebuilt the brakes, front suspension, cleaned/ lubed frame and swing arm componants.

Basically I'm ready to get an engine put back in, but I've run into trouble. The transmission feels "wrong" on the CA engine, while the crank is no good on the AZ engine (the one that was removed from the bike). Read up on the other post for details (I belive the CA engine to be 2008 or newer and don't know what parts are interchangable internally)

If anyone has any thoughts or knows of a good machine shop in PHX that I can take this case to to get new bearings and seals pressed in when I split the case, I would be greatful! THANKS

OH, Also for the Tengai Experts here... This is a picture of my bike, and the fairings I purchased are the "other" paint job style. Will These blues match? I assume not... Probably going to have to do a whole paint job if thats the case. Ideas?
Thanks again.
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post #2 of 108 Old 12-29-2019, 11:58 AM
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You should confirm the year of your replacement motor by going to watt-man's sight and cross referencing engine number. If the picture you posted of the head in the intro thread is the replacement head it is not gen 2 as there is no AIS port.
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post #3 of 108 Old 12-29-2019, 12:36 PM Thread Starter
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Quote:
Originally Posted by Klrian View Post
You should confirm the year of your replacement motor by going to watt-man's sight and cross referencing engine number. If the picture you posted of the head in the intro thread is the replacement head it is not gen 2 as there is no AIS port.
Well, ALRIGHTY THEN! Too easy. They are both "AE0" engines, so they are both Gen 1. Thank you! The only thing then is the extra gear thing, Looks like a kick gear. Hopefully no big deal.

Any idea about the "hard moving" transmission and how to possibly get it turning/shifting smooth again without cracking the case open?
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post #4 of 108 Old 12-29-2019, 06:52 PM
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The engine with the countershaft sprocket that is retained by a nut is '96-'07.

You can put the earlier transmission into the newer case, but cannot put a new transmission into an older case. The retaining clips for the earlier output shaft are somewhat rare, but not unobtainable. If the one you have is somewhat worn, get a new one or two.

The newer transmission is a five-dog and they have been known to bust a dog. That usually is clunky a quite shitty. You may simply have a rusty bearing.

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post #5 of 108 Old 12-29-2019, 06:55 PM
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Here's some info on transmissions:
https://www.souperdoo.com/stuff%20th...ion-comparison

Tom [email protected]

“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -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 #6 of 108 Old 12-29-2019, 07:16 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
The engine with the countershaft sprocket that is retained by a nut is '96-'07.

Dog?

You can put the earlier transmission into the newer case, but cannot put a new transmission into an older case. The retaining clips for the earlier output shaft are somewhat rare, but not unobtainable. If the one you have is somewhat worn, get a new one or two.

The newer transmission is a five-dog and they have been known to bust a dog. That usually is clunky a quite shitty. You may simply have a rusty bearing.
Sounds like what I want to do anyways then.. Take the Newer engines crank and put it in the old case with the older transmission (since the new transmission is having issues anyways. both are 5 speed I'm assuming.
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post #7 of 108 Old 12-29-2019, 08:46 PM
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Yes, dogs.



All the internals should move from the old case to the new without any issues.

Though, depending on the year, the transmission ratios varied somewhat the transmissions were always 5-speed.

Tom [email protected]

“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 12-29-2019 at 08:49 PM.
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post #8 of 108 Old 12-29-2019, 09:36 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Yes, dogs.

All the internals should move from the old case to the new without any issues.

Though, depending on the year, the transmission ratios varied somewhat the transmissions were always 5-speed.
Oh, I see. Thanks. I Thought those were called "shifter pawls" or were those forks... Eh. No biggy. lol

We'll, I was hoping to put the new crank into the old case because the CA air has put some REAL HELL on the New case. It would need to be completely stripped and painted... But if the New transmission is really that much better, then I'll do it.
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post #9 of 108 Old 12-30-2019, 12:54 AM Thread Starter
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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?
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post #10 of 108 Old 12-30-2019, 10:23 AM
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In my opinion, the new transmission is not a better transmission. I don't happen to believe that a 5-dog transmission is stronger than a three-dog. Kawasaki goes to lots of stuff that isn't necessarily better than what they had before. The dogs are what keep the gears in constant motion, yet allow some slack. A five-dog might be as strong as, or perhaps stronger, than a three-dog if it could be ensured that every dog was bearing 20% of the load at all times. Tolerances being what they are, there is likely a dog or two that is carrying no load, though. In a three-dog it is easier to ensure that the dogs are carrying their fair share. A single dog in a three-dog is stronger than a single dog in a five-dog.

The transmission is shifted by a shift drum and shift forks and a shifter cam. There are no pawls. That is Sturmey-Archer stuff.

The newer case is a better case, though. Have a look at this: https://www.souperdoo.com/stuff%20th...oe-s-crankcase
You'll see some spots where it was improved and made a bit stronger. Does it really matter? Meh, maybe not so much but it is a stronger case. Had they beefed up the drain plug area, that would matter.

But you know what opinions are like.

Tom [email protected]

“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -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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