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Old 06-28-2013, 05:49 AM   #7306
XDragRacer
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Joined: Mar 2009
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Quote:
Originally Posted by wparkinson View Post
Got a matched set of lower halves from a salvage shop....
What for?

A little J-B Weld, and you'd be good to go!

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Old 06-28-2013, 06:05 AM   #7307
wparkinson
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I don't know if you canget it by the 5 gallon bucket...

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Old 06-28-2013, 06:32 AM   #7308
Tsotsie
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Joined: Nov 2007
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Originally Posted by SuperGlueRyan View Post
Hello all - I've recently joined your ranks with the addition of a 98 KLR to my stable. It's my first dual sport and I have enjoyed it a lot so far...

Welcome to the ranks!

That is what it is all about - changing what does not suit you and then going out and having fun!
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Old 06-28-2013, 07:03 AM   #7309
XDragRacer
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Originally Posted by wparkinson View Post
I don't know if you canget it by the 5 gallon bucket...
Had 55-gallon drum in mind, wparkinson!
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Old 06-28-2013, 07:35 AM   #7310
wparkinson
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Old 06-28-2013, 10:28 AM   #7311
SkiBumBrian
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Prolly toasted you cam journals. Pull the cover and look at the exhaust cam (the one toward the front of the bike) on the left side, that is the last journal to get oil and the first to go. You can usually see the damage without pulling the cam caps. If not, pull the cam caps, you will probably find scoring and discoloration of the cap and head. There are a few shops that can repair the damage if not too severe.
Yes, there should be a crush washer on the plug, 17 ft. lbs.
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Old 06-28-2013, 11:34 AM   #7312
GoThere@50
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Straitenarrow,

Judging from the amount of metal in your oil filter pleats I would not recommend just heading out on a long trip, but it may not be as bad as it seems. The KLR bottom end is very robust, the key will be flushing it thoroughly. The conventional method of using multiple back to back low viscosity oil, and filter changes will eventually get the particles out. As 'SkiBumBrian' said remove the cam cover and look at your cams, check the bearing surfaces and cam lobes for burning or scoring. If they appear relatively unharmed, check the compression. After removing the spark plug to insert the compression gage adapter look in the hole with a flashlight to check the piston crown. If it's still a smooth carbon coated surface you may be OK. If your compression is at least 77 psi that will be another good sign. If all that checks out, flush it well and take it on a good test ride. Check to see if your KLR is puffing white smoke on engine braking or darker smoke under hard acceleration.

If the visual inspection reveals burned or scored metal surfaces or the piston crown looks pitted or spattered you would be well advised to rebuild the top end from the base gasket up. For not much more than the OEM parts you could go with the 688 or 705 cc bore kits consisting of an over bored cylinder or a cylinder with a custom liner and a forged piston with matching rings and gaskets. The KLR bottom end and midrange respond well to these kits and if you get the head ported or opt for oversized valves, so will the top end with an aftermarket exhaust system. The head option however, will raise the cost significantly, even above the cost of a used engine. It depends on how much you're willing to put into it and if the added performance means anything to you on the KLR platform. I took the latter approach (and then some) and can honestly say it was worth it for me.

Good luck! Hopefully your engine survived and your wallet won't loose weight.
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Old 06-28-2013, 11:56 AM   #7313
SkiBumBrian
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I feel very sure by your description of the vibration and noise that you have head issues, sorry. If you do attempt a compression test remember to disable the KACR (if you have one, mine is long gone). Doesn't sound like it jumped timing, just don't start it anymore until you assess the damage. Since the oil burning 08s heads have become rare and expensive. If you find damaged journals, take pics and send to Eagle Mike or Engine Dynamics and they can tell you whether it can be saved or not...
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Old 06-28-2013, 12:08 PM   #7314
straightenarrow
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Thank you so very much for the input thus far... you guys and the shop manual are invaluable. I will be posting what I find. I think tonight I may just relax with a case of beer and ponder how good I have it if this is my biggest problem :)
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Old 06-28-2013, 01:45 PM   #7315
IDRIDR
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Location: Boise, Idaho
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Originally Posted by straightenarrow View Post
I think tonight I may just relax with a case of beer and ponder how good I have it if this is my biggest problem :)
That, my friends, is a terrific attitude! We need more of those around.
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Old 06-28-2013, 03:11 PM   #7316
sandalscout
blah blah blah
 
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That, my friends, is a terrific attitude! We need more of those around.
No joke, HUGE smile creeped across my face when I read that!
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Old 06-28-2013, 08:39 PM   #7317
straightenarrow
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Location: Central Wisco
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Quote:
Originally Posted by GoThere@50 View Post
Straitenarrow,

Judging from the amount of metal in your oil filter pleats I would not recommend just heading out on a long trip, but it may not be as bad as it seems. The KLR bottom end is very robust, the key will be flushing it thoroughly. The conventional method of using multiple back to back low viscosity oil, and filter changes will eventually get the particles out. As 'SkiBumBrian' said remove the cam cover and look at your cams, check the bearing surfaces and cam lobes for burning or scoring. If they appear relatively unharmed, check the compression. After removing the spark plug to insert the compression gage adapter look in the hole with a flashlight to check the piston crown. If it's still a smooth carbon coated surface you may be OK. If your compression is at least 77 psi that will be another good sign.

Good luck! Hopefully your engine survived and your wallet won't loose weight.
Here is what I could see... top of the piston looked black.

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Old 06-28-2013, 08:43 PM   #7318
Whitebread117
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The cam lobe in pic 1 got HOT. Maybe no long term damage, but I would for sure check oil pickup screen and oil level before starting again. Maybe dodged a bullet, maybe in the middle of top end melt down. Good luck, you've got the right attitude
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Old 06-28-2013, 09:07 PM   #7319
SkiBumBrian
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I would still pull the caps... I can't really tell from the pic, but what is that laying on top of the KACR? Check your cam timing too...
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Old 06-28-2013, 10:13 PM   #7320
jeepsandbikes
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So i was going to sell my second klr but had nothing but flakes and lowballers sending me messages .. so i decided to trade this
https://www.dropbox.com/s/m2gfaeiwx3...2015.12.48.jpg
for this
https://www.dropbox.com/s/nf5qw88bxv...2014.24.42.jpg
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