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Old 07-29-2013, 11:09 AM   #1
pabloxt500 OP
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Joined: Nov 2009
Location: Los Angeles, California
Oddometer: 86
First time KLR owner

Hey Owners,
I just purchased a 2000 KLR on Saturday that has been sitting for 2 years.
Going to have a bunch of questions.
First and for most, the doohickey broke while the PO was riding it. He waited to long to replace it. :/
So everything is in boxes.
The bike comes with a gasket kit and the good replacement doohickey, along with 2 spare bottom ends.
One bottom end is good but came from canada and had the vin filed off. :/
The other bottom end looks good, but the crank is bad.
The original has a broken mounting stud near the doohickey location, so those cases are out.
Any way, I'm thinking after inspecting everything and finding all the parts that are usable, I can transfer the inner bits to the good cases, do a rebore and new piston kit.
Obviously i'll farm out the rebore, But should I just put it together myself? Or use a local shop?
I've put other motors together, but nothing this modern. So, would any of you recommend a shop in Los Angeles to get the engine rebuilt at? Can any of you estimate the rebuild hours?
The rest of the bike is fine. Only 25k on it.
Panels need to be cleaned up, new chain, new battery, but that is for the rolling chassis.
Any advice and comments are welcome.
Thank you

Mike
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1977 Yamaha XS650
1978 Yamaha XS400
1978 Honda CB550K
1970 Honda CT90
1965 Ducati Monza 250

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1978 Yamaha SR500- I miss it so much.
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Old 07-29-2013, 11:16 AM   #2
Tsotsie
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Joined: Nov 2007
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Welcome!

CA is the the home of several authorities on KLR's. Eagle Mike is in SD just down from you.

KLR a modern design? Is that a joke? Same old, same old basics for more that 22 years now.

You can do it if you have put a motor together before. Get a Clymer's manual if you need help..
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Old 07-29-2013, 11:24 AM   #3
pabloxt500 OP
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Joined: Nov 2009
Location: Los Angeles, California
Oddometer: 86
I consider it modern as I normally ride vintage. :)
(see signature below)
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Bikes in hand:
1978 Yamaha SR500 #119!
1977 Yamaha XT500
1977 Yamaha XS650
1978 Yamaha XS400
1978 Honda CB550K
1970 Honda CT90
1965 Ducati Monza 250

Sold off:
1992 Yamaha FZR600
1978 Yamaha SR500- I miss it so much.
1981 Yamaha Seca 550
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Old 07-29-2013, 11:56 AM   #4
APJ757
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Quote:
Originally Posted by pabloxt500 View Post
Hey Owners,
I just purchased a 2000 KLR on Saturday that has been sitting for 2 years.
Going to have a bunch of questions.
First and for most, the doohickey broke while the PO was riding it. He waited to long to replace it. :/
So everything is in boxes.
The bike comes with a gasket kit and the good replacement doohickey, along with 2 spare bottom ends.
One bottom end is good but came from canada and had the vin filed off. :/
The other bottom end looks good, but the crank is bad.
The original has a broken mounting stud near the doohickey location, so those cases are out.
Any way, I'm thinking after inspecting everything and finding all the parts that are usable, I can transfer the inner bits to the good cases, do a rebore and new piston kit.
Obviously i'll farm out the rebore, But should I just put it together myself? Or use a local shop?
I've put other motors together, but nothing this modern. So, would any of you recommend a shop in Los Angeles to get the engine rebuilt at? Can any of you estimate the rebuild hours?
The rest of the bike is fine. Only 25k on it.
Panels need to be cleaned up, new chain, new battery, but that is for the rolling chassis.
Any advice and comments are welcome.
Thank you

Mike
Now that is a project! Good luck!


Cheers
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Old 07-29-2013, 12:09 PM   #5
Grinnin
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Swingarm bearings often have a skimpy supply of grease and can be a bear to get apart. Since this is a procedure that requires penetrating oil and time, now may be a good time to set it up to poke at once every few days.

Even with only 25k miles on the bike the grease is 13 years old. You may want wheel bearings just because.

If you've worked on older engines then you should be fine with assembly.
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Old 08-21-2013, 01:50 PM   #6
pabloxt500 OP
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Location: Los Angeles, California
Oddometer: 86
leftside crank bearing

OK, i had this posted on the KLR650 forum but really wasn't getting any response. so I'm re posting it here.

everyone says that the bike since its creation didn't change until 2007. why can't i just buy the race and bearing from the 87-96 and install it?
both have the same part numbers for the left complete crank half. soooo.....?

another question:
i have a crank from one engine and different set of cases.
can i just put the crank in the other cases?
but wouldn't the roller bearing and race have worn different between the two?
OR should i just take the race out of the bottom end i got the crank from and install it into the good cases?
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Bikes in hand:
1978 Yamaha SR500 #119!
1977 Yamaha XT500
1977 Yamaha XS650
1978 Yamaha XS400
1978 Honda CB550K
1970 Honda CT90
1965 Ducati Monza 250

Sold off:
1992 Yamaha FZR600
1978 Yamaha SR500- I miss it so much.
1981 Yamaha Seca 550
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Old 08-23-2013, 07:28 AM   #7
Kawidad
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I must be missing something, but you said the Canadian sourced bottom end was good, but had the numbers ground off. I case you don't know, those numbers are the engine numbers and not a VIN. The engine numbers are irrelevant to the registration of the vehicle in California. If it worries you, you can re-stamp the engine number with the original number using a stamping kit from Harbor Freight among other outlets. Far easier than the alternative.
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Old 08-23-2013, 08:50 AM   #8
DirtyDog
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Quote:
Originally Posted by pabloxt500 View Post
...
Obviously i'll farm out the rebore, But should I just put it together myself? Or use a local shop?
I've put other motors together, but nothing this modern. ...
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Old 08-23-2013, 11:34 AM   #9
pabloxt500 OP
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Quote:
Originally Posted by DirtyDog View Post
i only ride vintage. so laugh if you will.
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Bikes in hand:
1978 Yamaha SR500 #119!
1977 Yamaha XT500
1977 Yamaha XS650
1978 Yamaha XS400
1978 Honda CB550K
1970 Honda CT90
1965 Ducati Monza 250

Sold off:
1992 Yamaha FZR600
1978 Yamaha SR500- I miss it so much.
1981 Yamaha Seca 550
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Old 08-23-2013, 12:48 PM   #10
Beezer
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there is one bearing in the bottom end that you apparently can't buy... think it's the left main. post some pix of the damaged case


Eagle Mike is a really good source of info on rebuilding the engine

also, some general info from Big Cee:

http://www.bigcee.com/klr650faq.html#generalinformation


1987: Crankshaft is unique to this year.
1988: Beefed up the engine cases with extra bolts between the crank and countershaft; crank has a different part number, and may be lighter.
1990: Countershaft improved with longer splines for increased engagement with sprocket.
1992: Changes to front brake master cylinder.
Mid-1996: Changed valve cover, added bracket to hold cam chain bumper; changed crank to heavier unit; improved clutch basket with more clutch plates; changed countershaft sprocket retainer from slotted plate to large nut; changed 2nd and 3rd gear ratios. Kickstarter no longer fits with new clutch basket. New left balancer weight/sprocket begins with engine #KLE650AE032206.
(?) Service manual indicates higher charging system output; only part number change is the rotor. The new power rating is 17A/14V (238 W) @ 7000 rpm; the earlier one was 14A/14V (196 W) @ 8000 rpm (yes, above redline).
2001(?) Assembly shifts from Japan to Thailand. Hard to say if there are any quality issues, as the parts still seem to be manufactured in Japan.
2007: New shift lever
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Old 08-23-2013, 08:29 PM   #11
pabloxt500 OP
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you can if you know where to look.
and i did speak with Mike just yesterday.
cheers.
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Bikes in hand:
1978 Yamaha SR500 #119!
1977 Yamaha XT500
1977 Yamaha XS650
1978 Yamaha XS400
1978 Honda CB550K
1970 Honda CT90
1965 Ducati Monza 250

Sold off:
1992 Yamaha FZR600
1978 Yamaha SR500- I miss it so much.
1981 Yamaha Seca 550
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Old 08-27-2013, 07:13 PM   #12
pabloxt500 OP
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Joined: Nov 2009
Location: Los Angeles, California
Oddometer: 86
so much done today:
frame drilled and better bolts installed
new Renthals
new grips
trunk base plate mounted
extra keys made
painted pannier rack
valve shims measured and ordered
new right side crank bearing ordered(already have the left/both pieces)

tomorrow:
layout panniers on rack.
remove wheels for new tires
remove swing arm for new bearings

question about the emissions cans.
can they be removed without re-jetting?
can you just block them off.
__________________
Bikes in hand:
1978 Yamaha SR500 #119!
1977 Yamaha XT500
1977 Yamaha XS650
1978 Yamaha XS400
1978 Honda CB550K
1970 Honda CT90
1965 Ducati Monza 250

Sold off:
1992 Yamaha FZR600
1978 Yamaha SR500- I miss it so much.
1981 Yamaha Seca 550
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Old 08-28-2013, 10:17 PM   #13
pabloxt500 OP
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Joined: Nov 2009
Location: Los Angeles, California
Oddometer: 86
coming along nicely.



__________________
Bikes in hand:
1978 Yamaha SR500 #119!
1977 Yamaha XT500
1977 Yamaha XS650
1978 Yamaha XS400
1978 Honda CB550K
1970 Honda CT90
1965 Ducati Monza 250

Sold off:
1992 Yamaha FZR600
1978 Yamaha SR500- I miss it so much.
1981 Yamaha Seca 550

pabloxt500 screwed with this post 08-28-2013 at 10:23 PM
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Old 08-29-2013, 05:24 AM   #14
Tsotsie
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Nice!
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Old 08-29-2013, 07:45 AM   #15
Kawidad
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Quote:
Originally Posted by pabloxt500 View Post

question about the emissions cans.
can they be removed without re-jetting?
can you just block them off.
Yes, just remove. No re-jetting is required.
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