KLR 650 Technical.

[princemouse]

My klr 650, 2007 model, has blown motor, a piece of what look like an expanding centrifugal metal disk located at the end of the exhaust cam shaft and seems to spin with the cam shaft, has expanded to much and come through the tappet cover. What does this part do? The original engine problem, the bike was run with no gearbox oil, and ceased. After the seize, the motor run but with a heavy tappet noise. What will have to be repaired/replaced to get it back to new?

[Mr mischief]

Not to sure, but reads like a de-compressor attachment, to aid kick-starting has failed.
About the lack of oil. . . that is likely to be nasty, lack of engine oil will more than
likely mean the engine has become scrap!

Inspect cam’ bearing surfaces by removing a camshaft bearing cap. It may also be possible
to remove the sump, look see if there is any metal flakes from the engine running without oil.

Best test if all looks OK then is - re-fill with oil, after fixing the failed component, then run the engine.

Mr mischief.

[my.klr.jr]

the same happend to my 89 klr250, that metal disk is the decompressor, it isnt essential but does make starting easier.

If you choose to leave it without the decompressor when starting you will have to slowly push it past the compression stroke(assuming kickstart model) and then kick it, if you dont push it past the compression stroke there is a chance that you might snap the kickstart shaft so be careful.

Once you have it going again, buy some new oil filters and clean and change them every few k's when first ridden. Then regularly after running in. there will be alot of iron filings in there!!

REMEMBER: check the valves regularly, valve train failures are the #1 killers of all KLR'S!

mine has been run out of oil twice but now is going better than ever,

[princemouse]

Yes, thanks for the info, have someone rebuilding for me. He knows the bike well. Bought a crashed KLR and used the parts to fix mine, then will sell off the rest piece by piece.

[Saleenguy]

Be sure to replace the DOO on the newer motor if its not already done.
Because the lever and spring are prone to breaking, and sending shrapnel thru the motor.
Its cheap, and easy to do.
Order it from Eaglemike, he can be found at KLR650.NET - Your Kawasaki KLR650 Resource! KLR650 Forums, Photos, Mods & Tech search eaglemike.

Go against what the manual says and run only 20w50 oil in the KLR650, as the lighter oils like 10w30 are too thin to protect it in the heat.

PM me if you need help, I have had lots of these motors apart.

If you decide to do an overhaul I strongly suggest the 685 kit from Kary, he is also on the klr650.net site.
More power, way smoother, and never uses a drop of oil.

Best of luck to you.
And check the oil level in the window every time you fill up with gas, a few klr650's use oil, if you got one of them, it can burn a lot.
The oil burners seem to be about 2 or 3% of the bikes.