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Old 10-25-2008, 04:58 AM   #1
juames OP
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Klr650 Help!!!

Out for a beautiful fall ride yesterday with my riding buddy on his '03 KLR650...had a great day! On the way home though his mean green machine started to make the worst sound ever! A vey loud banging/clanging noise from the top end...kept running...no loss of power...no smoke...no warning...just a veeeery loud clanging noise. We decided not to push things, so we arranged to truck it home...any ideas?
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Old 10-25-2008, 05:09 AM   #2
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Pull the valve cover off and take a look.
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Old 10-25-2008, 05:32 AM   #3
juames OP
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That's gonna be our first move...could the cam chain have slipped maybe? Is that possible?
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Old 10-25-2008, 06:07 AM   #4
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Quote:
Originally Posted by juames
That's gonna be our first move...could the cam chain have slipped maybe? Is that possible?

broken bits of the doohickey spring have been known to make the cam chain jump a tooth or two.

the KACR has also been known to self destruct and start flopping around inside the head.

the KACR is on the right exhaust valve. some people have completely eliminated it.
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Old 10-25-2008, 07:56 AM   #5
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Sorry...what is the KACR? And I guess the only way to know is to take the head not just the valve cover right?
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Old 10-25-2008, 08:26 AM   #6
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The KACR is the kawasaki auto-compression release. It's a leftover from kickstarts that cracks an exhaust valve a hair at very low RPMs to help the engine turnover. In an e-start world it lets the starter more easily turn over the engine. They were a common failure in the older 600s and the KLX's, but it's really rare (though of course not unheard of) to have one fail on a KLR.

You can remove the valve cover without tremendous difficulty, but it does require pulling some other crap first. Check out the KLR FAQ http://www.bigcee.com/klr650faq.html which also has links to a pictorial step-by-step of how to check the valves (which, of course, involves removing the valve cover).

Without having a look in there all guesses as to your noise are just shots in the dark.

Luke
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Old 10-25-2008, 08:31 AM   #7
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Kawasaki Automatic Compression Release

it's on the end of the cam, so you only have to pull the valve cover to inspect it... not the whole head.

anyway, it's a little widget with centrifugal weights that keeps one exhaust valve slightly open at low RPM, makes starting easier.... remember that the 600 originally had only a kicker, and the kicker was also a factory option in the early years.

the KLR 250, which is kick only also has the KACR.

it's not quite the *ahem* amazing piecte of engineering that the doohickey is, but sometimes it still goes kablooey.

pull the valve cover and see if it's been beating itself against the inside of the cover.
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Old 10-25-2008, 09:02 AM   #8
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OK, and for the Doohickey if we drained the oil we should get some metal fragments right?
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Old 10-25-2008, 09:11 AM   #9
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sometimes you can get either broken bits of the doohickey lever and/or spring out inthe oil... sometimes not.

to check, you really need to pull the left side covers off, and then you can peek under thr rotor... but you can't get a direct view of the whole thing without pulling the rotor.

doohickey destructions with pix here- http://www.klr650.marknet.us/doohickey.html

valve clearance destructions with pix here - http://www.klr650.marknet.us/valves.html

in Canada, you can get the doohickey and tools from A Vicious Cycle
http://www.aviciouscycle.ca/klrdoo.html
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Old 10-25-2008, 12:23 PM   #10
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thxs...will let you know what it turns out to be!
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Old 10-25-2008, 05:22 PM   #11
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noise

Was the doohickey ever replaced on this machine? How long ago were the valves adjusted?
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Old 10-26-2008, 05:08 AM   #12
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The bike has 20k on it, he's had it for 4k and hasn't replaced the doohickey or checked the valves...
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Old 10-27-2008, 12:10 AM   #13
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Quote:
Originally Posted by juames
The bike has 20k on it, he's had it for 4k and hasn't replaced the doohickey or checked the valves...

20,000 kilometers?

ouch!

with no clue what the valve clearances where when purrchased, the valves should have been checked long ago. same for the doo.

that's not meant more as a sidebar for anyone else planning a purchase like this, not to bash the owner of this bike.
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Sit tall in the saddle, Hold your head up high
Keep your eyes fixed where the trail meets the sky
And live like you ain't afraid to die
And don't be scared, just enjoy your ride.

"... in my version of Heaven you get all your dogs back." Mista Vern
"Old dogs don't die, they just wait for you in another place." Twilight Error

I'll show you a place, high on a desert plain, where the streets have no name.
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Old 10-27-2008, 05:25 AM   #14
juames OP
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So thought'd you like a little update...valve cover is off and cam chain must have jumped...at TDC the lobes are not where they are suppose to be! Drained the oil and no metal showed up...took side off but can't get a look at the doohickey or spring...don't have the right tools...ordered the Eagle Mike replacement kit that comes with everthing need to replace stock. One question though...should we try to check the valve clearance before we replace the doohickey and reset the cams to thier proper place, or after we've done all that work? Actually two questions...we ran the bike for a minute after it started making the noise...do you think that damaged the valves or something else?
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Old 10-27-2008, 07:33 AM   #15
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I would check valve clearance before taking it apart so you know what shims are needed.
Jim
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