Engine swop - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

  • 1 Post By DPelletier
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post #1 of 5 Old 04-19-2020, 10:21 PM Thread Starter
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Join Date: Apr 2020
Location: UK
Posts: 2
Cool Engine swop

I'm thinking of putting a year 2000 KL650AE engine into my 1989 KLR 650 Tengai currently also KL650AE. Are there any issues I should look out for? It physically looks like a direct swop but what about the carb? Will the original fit? Do I need to change the stator? Stator cover? many thanks Regards
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post #2 of 5 Old 04-20-2020, 01:23 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,511
The Gen 1 "A" series engine should exchange directly into your Gen 1 "B" series chassis & plug directly into the wiring & fuel system with Zero alterations, IIRC.

And welcome to the forum.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 5 Old 04-20-2020, 04:29 PM Thread Starter
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Join Date: Apr 2020
Location: UK
Posts: 2
Thumbs up Engine swop ve rebuild

Many thanks for the information and the welcome!
I am in the process of rebuilding my 1989 KLR 650 engine. Having now completely dismantled it, its clearly had a very hard life and needs a considerable amount of love and cash to bring it up to scratch. Crankshaft needs a pin and con rod set, I might as well replace all the bearings and seals in the case as a matter of course, Gearbox fork selectors are on the limit, the piston looks very ropey and the barrel need a bore. All in all a engine replacement is a cheaper option, hence my post and its worth considering, but its the rebuild that is the really interesting bit for me. The one problem that concerns me right now is that the bike has been bottomed out on the deck and has cracked the aluminium around the drain plug ( a classic KLR problem it seems ) and the old repair done at some point has not been done well - Ill try and get a few pics of it in the album section. If you are interested I am posting videos on you tube about the rebuild - Slow TV I think they call it! - search; the motorcycle shed, or KLR 650 engine rebuild.. Ill post the vid of the case in the next couple of days - I need to get the casing repaired or get another one, can't decide if I need a 'pair' or just a single replacement if I can't get it repaired. Ebay is a source, but without looking direct at it in hand, I'm buying another load of issues I think. Regards
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post #4 of 5 Old 04-20-2020, 05:00 PM
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Join Date: Aug 2010
Location: Kelowna, B.C.
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Given the case damage, I'd say an engine swap is a bit of a no-brainer.

2 cents,
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post #5 of 5 Old 04-24-2020, 02:49 PM
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Join Date: Jan 2020
Location: Missouri & Colorado
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Anyone know how the Gen 1 A model shock differs from the B model Tengai shock?
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engine replacement, engine swop

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