Oil-burning KLR solved

[Timo Explorer]

To all those who have experienced or worried about the urban legend regarding the newer KLRs and their high usage of oil. We may have a solution.

We have two '08 KLRs, love them both. On our 10,000 kilometre trip to Newfoundland this past summer we experienced the high oil consumption that we have all heard about. We used about 500ml (1/2 quart) for each 1000 kilometres of highway driving. I did not really consider this alot, just that we had to keep an eye on it and keep it topped up. Also meant we always carried a couple of litres of oil with us wherever we went. Sort of became par for the course. Enjoy the KLR, but carry extra oil.

My son just got back from a 14,000 kilometre trip to baja. Here is the ride report: http://www.advrider.com/forums/showthread.php?t=427503.
On this trip he made a startling discovery. Keep in mind that he always keeps his oil topped up to the upper level in the sight glass, kinda anal about it really, but thats a good thing.
First, motorcycle oil is hard to come by in Baja, also chain lube even at bike shops??? Second and most important was that if the oil was kept at the BOTTOM level of the sight glass, he did not use nearly as much.

The science behind this is that when the oil is topped up and then the engine heats up and the oil pressure increases, it actually spits out the oil through the vent to a level that the engine actually likes and stays there.
Once you find out where your engine's happy place is, it will use very little oil consumption. This may take some trial and error, hopefully not bad errors, but I would suggest actually running less oil than dictated by the sight glass as the optimal level. You should always check your level, but experiment to find out where the engine is happy.

On this trip to Baja, he used 5 litres to cross the USA to get to Baja. Once this discovery was made, he rode the whole length of Baja and back and then returned across the US using only 2 litres. I would say that is significant.

Considering that the boy is one of the few riders with over 25,000 kilometres on an '08 KLR, he has gained some knowledge and insight into the workings of this wonderful bike.

This may not be the complete solution, but it worked for us. Try it.

[LILBIT]

It's not uncomman for engines that use oil to use much less at lower levels. I've seen problems with engines at WOT for more than a few seconds when run at lower levels. Your KLR may be fine but without an accurate pressure gauge it's hard to know for sure.

[Silver King]

Have either of you considered doing the PCV mod?

[CaptTurbo]

Or ... you could buy a DR and not worry about burning oil.

[McB]

I suspect if you overfill most any big thumper it will blow some out the breather. Keep overfilling it, and it will keep doing it.

If your oil consumption stopped being excessive when you stopped overfilling it, most likely you got one of the KLR's without the excessive oil usage problem.

There are enough stories out there to suggest that for some KLRs it's a real issue, not an urban legend. It's highly unlikely that all of the people experiencing the problem were merely overfilling it.

I was interested in getting an '08 until I read continuing reports of oil consumption issues. There was one in the flea market that was close and looked interesting; but then I read the guy's other threads about deciding to get rid of it because of its oil consumption. Another one I looked at was also promising, except for the seller's vagueness when I asked about oil usage.

I've heard the problem is corrected for '09 and hope that's true. I'd be interested in owning one except for that issue.

[BlueBuell]

I can see how a lower oil level would relieve some of the crank case pressure, and possibly reduce consumption.
My 08 has 8,000 miles on it, and uses a very small amount at extended freeway speeds. Something like a couple oz. in a few hundred miles.
I feel like I am lucky, after some of the 1/2 qt. every tank stories I have read.
Its an incredible bike. I should do the breather upgrade.
Cheers

[Watson]

I'm not gonna start knockin' KLR's, but I think the oil consumption deal is beyond "Urband Legend." It's being reported far too often to be a myth.

Anyway, interesting write-up....could be on to a symptom to a bigger issue.

[Clayjars]

Kawasaki orders a hone job and new rings for the ones under warrantee. Given that... Any oil burner is going to need new rings and a re hone. No wishing away the problem.

[fixer]

if the mileage in the states was all highway miles, and the miles south of the border were on dirt, the difference in RPMs north and south of the border could explain the oil consumption.

[fixer]

Originally Posted by Clayjars

Kawasaki orders a hone job and new rings for the ones under warrantee. Given that... Any oil burner is going to need new rings and a re hone. No wishing away the problem.

not just "new rings", but IIRC, a different type of rings than the '08s originally shipped with.

[Silver King]

Originally Posted by fixer

not just "new rings", but IIRC, a different type of rings than the '08s originally shipped with.

correct

[NC Rick]

Lower oil level = less "windage" (where the rotating assembly whips up the oil by contacting it) so there could be less oil on the cylinder walls to get past the rings and burn? I can not see any oil pressure change from the level being high.

[Clayjars]

I worked in manufacturing for a while and saw problems like this once in a while. It would go like this. Part sourcing would fine some cheap vendor in Bolivia or such and insist that the ultra cheap part would work just fine. After product testing sure enough it was working. When the batches starting rolling in, an intermittant variance in spec or quality became apparent after it was too late. That is when one of those Saudi style beheadings would be timely in the parts sourcing department. Those guys can kill a product line over a potential 10 cent cost savings.

[markjenn]

This "self-seeking oil level" phenomena is well documented with many bikes. If you have a bike that is using oil, its always a good idea to see if running it nearer the low limit helps.

But..... never assume that this will happen for your bike. Consumption may taper near the low limit, or it may stay the same (or even increase) so you need to monitor it closely as it's getting low. And make sure your oil-checking procedure is consistent from check to check so you're not accidentally overfilling.

It's all about learning the idiosyncrasies of your particular bike.

- Mark

[Silver King]

Gawd! It's like riding an old Harley all over again.