First, Big Thanks to all who offered advice & Help!
Last summer I rode the Trans Wisc Adv Trail, I was following a big KTM on gravel roads & having fun playing flat track racer around all the bends. I had the darn thing redlined constantly. It Was the 1st trip riding my 1st KLR & I was amazed at how slow the darn thing is!! Could hardly get rear wheel spinning in gravel to slide around (BTW VERY Dusty). I made it 60 miles from Lake Superior when guy behind me mentioned all the smoke coming from exhaust. I turned & headed toward home, burned 4 its of oil in 150 miles!! But no engine mechanical noise heard.
So, that was my situation, expected to find something really bad upon disassembly.
Findings:
1) Uni brand Foam air filter was filthy - outside AND inside. I dont think the previous owner applied ANY filter oil to the Uni. I Bought bike w/ 5000 miles, & it had newish filter in it & thought all was fine - Shame on me!
2) Piston & bore are not nearly as bad as I expected, light scuffing. I think I could install rings, hone & use as is.
3) Pulled head - horribly carboned from burning all that oil, But no apparent or catastrophic visible damage. I was perplexed, what the heck IS the issue??
4) Poured kerosine in all 4 ports, it ran freely thru the rt Ex valve. I removed valves, both ex valves & seats aren't sealing, but no significant issue. IE no bent valves, cracked seats etc.
Conclusions:
1) I need Valve job & could use advice on where to take or send head (I am in Chicago area)
2) Decide whether to hone cylinder and replace rings or Buy the Big Bore kit - I hate to spend the $$ needlessly, but the kits sound great, so probably will get one.
3) Install or implement other Mods I am learning about - Airbox, Carb needle, Muffler Mod or new pipe. And anything else that easy & cheap.
Thanks again, need to find a machine shop...
Jack