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Norm, if you are going through all the trouble to replace rings why not just go with a new piston and rings, save yourself some time and stress? If you are needing rings the cylinder probably needs bored so i would spend a little more money and go with all new lighter modern parts......
 

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An intriguing mystery . . . Kawasaki manufactured Generation 1 piston rings for 21 model years (1987 through 2007 inclusive); then, suddenly, all spare and repair Generation 1 ring sets disappeared!

One might think a few, "new old stock" piston ring packages exist, gathering dust on the back shelves of some dealership parts department . . . oh, wait; dealerships typically don't carry any spare and repair parts any more; instead, relying on factory warehouses to hold their inventory . . . "Don't have it in stock, but I can order it for you!"

Did Kawasaki have such an effective "just in time" production schedule, THEY had no stockpile of piston ring sets? Or, did Kawasaki junk a mountain of piston rings, just to get rid of a line item?

Reckon we'll never know. Generation 1 piston rings shall always now be made of unobtanium, or a quite similar alloy.
 

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Has anyone identified a source for replacement rings for the earlier Gen1 piston?

I've begun looking several times but without success.
Normk,
Over on .net, in '08-'10, Xdragracer or Extreme sourced some "useable" Hastings rings for the 2008 and ups.

Looking at KLR service manual the top 2 rings are the same width for both pistons. (1.17-1.19mm)
Couldn't the expander ring be reused? That just leaves the oil rails.

Where they/he may have gone wrong was to uses Two 'Barrel-faced' top rings. Hasting #46835.
The second one needed/needs to be chisel faced or napier, what ever is the proper terminology.

2008-up Hastings Expander #48890 (.0578inch), TOO narrow for 2007-back.

2008 (Only, Maybe?) Hastings Oil Rails #48354 (.018inch)
Do I remember the 2009's were .020inch???
There may be a difference in oil rail 'depth' (old - new), due to type of expander.
Do you still have the 30+ Wyman Winn pistons?
 

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Discussion Starter #5
I am a retired technician and engine machinist so "stress" isn't a particular concern but thank you for your concern. As for "time and trouble", pulling a KLR engine down isn't either particularly time consuming or "trouble", but again, thanks for your concern.

On the other side, of the coin, it does provide an opportunity to study the oil consumption issue from another perspective which I hope meets with your approval?

I have also undergone "trouble, time and stress" as you phrase it, in wiring studies, piston studies and other aspects of motorcycle service such as developing a diagnosis and repair practice for repairing ABS modulators at a cost of $100.00 when the owners could just as well purchase new ones for $3,000.00.

I suppose the answer is that I'm simply irrational. :)




Norm, if you are going through all the trouble to replace rings why not just go with a new piston and rings, save yourself some time and stress? If you are needing rings the cylinder probably needs bored so i would spend a little more money and go with all new lighter modern parts......
 

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Discussion Starter #6
Yes, I have the Wyman pistons + a bunch more. I've been giving pistons to people who had earlier pistons and didn't need to rebore. That allowed purchase of rings but has depleted the supply so don't know how many are still here.

I suppose I should do some mix and match + buy some of the Hastings rings to check out. As most of this is simply to help others I'm a bit less motivated to spend money on gestures. The problem continues as "chicken and egg"though, because when one does come to do a re-ring I don't have an alternate available.

A friend is in the process of pulling his engine down and plans to increase the oil return hole size as I've been doing + he hopes to replace rings and deglaze rather than to rebore as the cylinder does not appear to be worn to a significant degree.

My recollection of the piston study is that oil rings were generally the main issue in terms of wear. Maybe I should drag them out again and refresh.





Normk,
Over on .net, in '08-'10, Xdragracer or Extreme sourced some "useable" Hastings rings for the 2008 and ups.

Looking at KLR service manual the top 2 rings are the same width for both pistons. (1.17-1.19mm)
Couldn't the expander ring be reused? That just leaves the oil rails.

Where they/he may have gone wrong was to uses Two 'Barrel-faced' top rings. Hasting #46835.
The second one needed/needs to be chisel faced or napier, what ever is the proper terminology.

2008-up Hastings Expander #48890 (.0578inch), TOO narrow for 2007-back.

2008 (Only, Maybe?) Hastings Oil Rails #48354 (.018inch)
Do I remember the 2009's were .020inch???
There may be a difference in oil rail 'depth' (old - new), due to type of expander.
Do you still have the 30+ Wyman Winn pistons?
 

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Hastings Rings?

Had a little time to kill, a carburetor is soaking.

I am certain that some where, back when, that I did read a slightly newer posting by Xtreme, about the possible napier faced 2nd ring.
KLR650.NET Forums - Your Kawasaki KLR650 Resource! - The Original KLR650 Forum! - View Single Post - Custom 08 Replacement Ring #'s here.
This is a single posting from Maintenance and Mods.

Normk, I don't think you would have to 'log-in'. I have to log-in to 'even read' from (87-07) and (08 and up) for some reason.
 
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