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Discussion Starter #1
Been riding for 20+ years, but don't recently got an "adventure" bike. 1990 KLR Tengai... Interesting looking, but it's missing some things. Motor is blown too.. Going to need some help getting it put back together!
 

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Welcome to the forum, ironranger88.

Go to the 'TOOLS' tool bar and 'User CP'. Include your city & nation in your personal profile. This info will help us help you for parts access.

First thing to acquire for the project is a Clymer repair manual or possibly a used copy of the OEM Kawasaki Tengai manual, part #99924-1113-01 or -02 or -03. I don't know if there were any more than 3 years production of the Tengai for any country.
 

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Discussion Starter #3
Welcome to the forum, ironranger88.

Go to the 'TOOLS' tool bar and 'User CP'. Include your city & nation in your personal profile. This info will help us help you for parts access.

First thing to acquire for the project is a Clymer repair manual or possibly a used copy of the OEM Kawasaki Tengai manual, part #99924-1113-01 or -02 or -03. I don't know if there were any more than 3 years production of the Tengai for any country.
Great, Done..
No, I don't think they made more than the three years, so it'll be a fun game trying to find em, also it looks like the timing belt snapped and cracked the valve cover, so I've got that going for me too... lol
 

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hmm.. Picture isn't uploading..
The forum prefers that you have at-least 15 postings to allow links & pics, because of spammers! To know that you are a legit KLRista.
 

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Why get in a rush? Kick back, read a bit. Respond when you feel the need. Enjoy the forum.

Welcome to the forum!
 
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I edited your original Post #5 to include the picture. Do you have a picture of the entire bike itself? Add it the same way and we can fix the post to show it.

.
 

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Discussion Starter #13 (Edited by Moderator)
Sweet! Well, here are some spam picks. She needs some serious love. Pulled it apart a little ways and it looks like the exhaust cam is pretty wounded, Timing belt is snapped too. Didnt see to much damage otherwise... hoping I can get away with just finding an exhaust cam and timing chain. I'll know more when I pull the left side off (once my service manual comes in)



 

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Discussion Starter #14
Any ideas where a guy could find a reasonably priced exhaust cam? $70 seems steep used (eBay prices)
 

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You will likely need more than an exhaust cam. There shouldn't be a gap between the head and the cam cap. These cam journals may be hammered pretty badly. If they are they will never be able to hold oil pressure again.



The cam chain is pretty tough on these things and seldom breaks in service. If it has then there may be bent valves as the engine is an interference design. That would show as a huge amount of valve lash (gap between the heel of the cam and the surface of the shim) due to the valve stem being bent from the valve hitting the piston, preventing the valve from closing.

There is an outfit in Petaluma, CA, Engine Dynamics, that may be able to fix the head for less than the cost of a replacement head. Replacements are getting quite spendy and a bit hard to come by due to the high incidence of head explody events on the 2008/2009 bikes.

The good news is that any head you might find, 1987 to the present, would work as a replacement. You'd need a blocking plate on the AIS port for a 2008+ head, but that is trivial.

Best to get the cover off of the head and see what's what in there and assess the whole situation.
 

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Tom must of stayed up way later than intended. :)

I'll suggest that if the valve cover has not been completely removed yet and you turning the engine over and not seeing the EX Cam turn, it may be because of a Sheared locator pin on the EX sprocket to cam interface. Not necessarily a broken cam chain.

With the heat discoloration seen on cam lobe & the gap of the RH bearing, the most likely suspect cause for damage is Severe Lack of oil level in the crankcase.
When the bearing got worn soo baadly due to lack of oil supply, the centrifugal operated automatic compression release mechanisim snagged the head and valve cover and that sheared the locator pin as well as exploded the KACR.

But it appears that the main casting of the cylinder head is not broken, so as Tom said Engine Dynamics should be able to repair the damaged bearings a Whole Lot cheaper than purchasing a new head. Click on this, ENGINE DYNAMICS
 

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Yes, Triumph have announced the new Tiger 900 and I was up late (or early, depending on your point of view) having a chat about that. The forum is UK based and it's most active during UK daylight. At least they speak English, unlike the German KLR forum.
 

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SO HERE WE GO! Picked up the Tengai today. Here is what I found.



https://flic.kr/p/2hUcS2V
The leaning RH valve cover bolt in this pic and its associated mounting tower is also of concern. You will need several pics sent to Engine Dynamics for them to access the damage after you get it disassembled.
 

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Discussion Starter #19
Well alrighty then! Thanks guys.. I'm off to work for a week (long work trips) and have a couple of days off after that. So I put it up for sale to see if anyone has any interest (who knows what they're doing). $800 obo if anyone in Phoenix Is interested. Haha
I am curious to see is it is indeed that bolt though.
Bolts are easy to replace. I have a local guy that can do most of that repair work and Machining, but I'm still at a lokk about the thing on the end of the cam. What is that called? (The exploded part on the exhaust cam)

Thanks again for the responses
 

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K.A.C.R. , Kawasaki Automatic Compression Release.

A cylinder de-compression device which allows the use of smaller lighter, battery / starter motor / gears. Only decompresses at less than normal idle speeds.
 
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