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Discussion Starter #1
I have a 2008 KLR with a seriously blown engine and am going to get a used or rebuilt engine. My question is: what year engines are plug and play with a 2008 KLR650? I know that 1st gen engines are out. 2008 is obviously fine. Are newer engines a direct swap?

Thanks!
 

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Truth be told, all engines are a direct swap if you re-use the 2008 left side outer cover with stator and the rotor. This is really quite simple. These are the two engine components that are affected by the change in ignition system from Gen 1 to Gen 2. All the other changes do not hinder interchangeability. Otherwise, 2008+ is a true plug and play.

In order of desirability:
2010+; avoids the oil burning issue
1996-2007; have all the '96+ improvements and can be bored for 685 kit. Damn good motors.
1987-1995; will work, but generally cannot be bored much. No Gen 1 stock rings are available for 1987-2007, but these can only be bored to about 658. They have less meat in the cylinder/liner. Also have the toothed plate countershaft sprocket retainer.
2008-2009; once cleaned up to remove all petrochemicals they make a fine boat anchor.
 

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Some 2008 and 2009 models can be prone to consume abnormal amounts of engine oil, maybe that is what happened to yours?

I'm reasonably certain 2008 thru 2017 should be 'plug-n-play'.
 

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.....2008-2009; once cleaned up to remove all petrochemicals they make a fine boat anchor.
Oh Tom,,,, Not all,,,, My 2009 only used about a 1/4 of a quart (if that) between changes and that was with a 14 tooth. The 2014 1/2 used none between. Not much interstate. Both bikes spent a lot of time a 55 MPH through curves and were washed once each. Traded the 14 with mud included. Never did the Doo or thermobob on either bike. Lubed the chain once in a while. Did some mods on the 09 but the 14 was left almost stock. Never seemed like any mod was worth the effort. Gas, oil changes and tires was about it.
 

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Discussion Starter #5 (Edited)
Thanks for the complete reply, Tom. If I go the replace route, I will look for a 2010 or newer engine. Before going that route, I will tear down my engine to see if its condition is not truly terminal. If that is the case, I will repair it and go with one of Eagle Mike's piston kits to reduce the oil consumption.

Yes, oil consumption was at the root of my problem. I found out that it ate the stuff at a truly prodigious rate (> 1 qt in 500 miles). The consumption got away from me and grenaded the engine.
 

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Oh Tom,,,, Not all,,,, My 2009 only used about a 1/4 of a quart (if that) between changes and that was with a 14 tooth. The 2014 1/2 used none between. Not much interstate. Both bikes spent a lot of time a 55 MPH through curves and were washed once each. Traded the 14 with mud included. Never did the Doo or thermobob on either bike. Lubed the chain once in a while. Did some mods on the 09 but the 14 was left almost stock. Never seemed like any mod was worth the effort. Gas, oil changes and tires was about it.
True, not all. Enough, though, to make one pause before buying one. Especially if there are other options.

I have had an '08 and an '09. Both burned oil. It's highly unlikely that I'd bother buying another.
 
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Not threadjacking (much) but like Toney, I got a "good" '09 too.

Uses very little. Maybe a quart, (a few ounces at a time), per oil change interval.
I run the tachometer all over the place.

Even the 08's aren't normally that huge of a burner as listed above by Gene.
His total came out to +1 qt every thousand miles. That's almost a 2-stroke !! lol
Seriously even a well maintained '08 or early '09 will be fine, even more so if the
cylinder gets cleaned up.
 
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