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I'm getting ready to do a 685 conversion to Sparky, my '09 KLR.
I'm looking for advice on things to do while I have the motor apart anyways. My bike has 36,000 miles on it, I bought it used with 33,000 miles on it. I've read that with the 685 conversion I should get the doohicky and thermo bob. My carb is already jetted and the engine runs rich, and I have a 16t front sprocket. Is there anything else I should do while I tear apart the engine?
 

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I would suggest that you buy new dowel pins for use under the cam caps. Mine were really being difficult: couldn't get cam caps back on...old pins wouln't seat correctly. Eagle Mike sent me some new pins, and it worked sooooo much easier. If I ever do another 685 kit, I'll have new pins on hand BEFORE I start the reinstall.
 

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I'm getting ready to do a 685 conversion to Sparky, my '09 KLR.
I'm looking for advice on things to do while I have the motor apart anyways. My bike has 36,000 miles on it, I bought it used with 33,000----- Is there anything else I should do while I tear apart the engine?
SkidmarkRVA,
Yes, there are a few modifications that I would 'highly recommend'.

But as a minimum I'll say #'s 8, 9 and 10 from this thread and its related threads,
http://www.klrforum.com/1987-2007-wrenching-mods/48377-pdw-oil-flow-mods-order-importance.html
 

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I would suggest that you buy new dowel pins for use under the cam caps. Mine were really being difficult: couldn't get cam caps back on...old pins wouln't seat correctly. Eagle Mike sent me some new pins, and it worked sooooo much easier. If I ever do another 685 kit, I'll have new pins on hand BEFORE I start the reinstall.
Removing the head for the 685 kit is not related to removing the cam caps for shim changes. You can do either without the other. I know you had some trouble with tight dowel pins, but that was abnormal. I have done 130,000 miles of shim changes and one 685 kit and am still using all the same pins.

As you are aware the pins for the head and the the cam caps have different part numbers and it seems like a good idea to keep them separate.
 

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Removing the head for the 685 kit is not related to removing the cam caps for shim changes. You can do either without the other.

I have done 130,000 miles of shim changes and one 685 kit and am still using all the same pins.
GoMotor,
I can't figure out how one could possibly get the cam chain off of the sprockets to get the cylinder head off of the engine cylinder with out first removing the cams, therefore removal of the bearing caps?

As to the cam bearing dowel pins, I agree with you GoMotor.
With even a little care and patience they should never be damaged, and never need changing.
 

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GoMotor,
I can't figure out how one could possibly get the cam chain off of the sprockets to get the cylinder head off of the engine cylinder with out first removing the cams, therefore removal of the bearing caps?

As to the cam bearing dowel pins, I agree with you GoMotor.
With even a little care and patience they should never be damaged, and never need changing.
I was assuming that removing the cam chain tensioner would give enough slack. It has been several years since I removed the the head on my 2008 for a 685 piston, so I'll take your word for it.

I keep the disposable kitchen container and baggy people in business when removing small parts from anything, so I don't lose then or mix them up.
 
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