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General Category => General Discussion => Topic started by: Chuck in Indiana on January 06, 2018, 12:45:49 PM

Title: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 06, 2018, 12:45:49 PM
Austin is learning that the least expensive motorcycle you can buy just might be the most expensive.  :grin:
He's getting some valuable mechanical experience from it, though. For a "simple" single cylinder bike, they sure are complicated.
Getta Guzzi.. :evil:
(https://farm5.staticflickr.com/4637/38832099054_403945720e_c.jpg) (https://flic.kr/p/22asEad)2018-01-06_01-36-03 (https://flic.kr/p/22asEad) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Title: Re: Explosion in a KLR factory ngc
Post by: twowings on January 06, 2018, 12:47:29 PM
Hmmmmm...probably needs more pin-up calendars and a beer fridge... :cool:
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 06, 2018, 12:50:31 PM
Hmmmmm...probably needs more pin-up calendars and a beer fridge... :cool:

You can just set your beer outside. Not for long, though..  :smiley:
Title: Re: Explosion in a KLR factory ngc
Post by: oldbike54 on January 06, 2018, 12:50:53 PM
 KLR for sale , all of the hard work done , only needs the carb cleaned .

 Dusty
Title: Re: Explosion in a KLR factory ngc
Post by: Darren Williams on January 06, 2018, 03:59:18 PM
I had a couple of mid 2000 model KLRs. I learned they are not the "stone axe reliable" and "dirt simple" bikes many of their devoted following would have you believe. The list of their short comings are enormous!  Kinda reminds me of some other motorcycle brands where you have fix a bunch of things before the bike will be semi-dependable and perform OK, not mentioning any names.   :evil:.
Title: Re: Explosion in a KLR factory ngc
Post by: Sasquatch Jim on January 06, 2018, 04:01:35 PM
 It ran when parked.
Title: Re: Explosion in a KLR factory ngc
Post by: fotoguzzi on January 06, 2018, 05:21:06 PM
shoulda got a DR  ?

(https://photos.smugmug.com/DR-650/i-GFM9TTb/0/a5ed698b/L/IMG_2002-L.jpg) (https://fotoguzzi.smugmug.com/DR-650/i-GFM9TTb/A)

(https://photos.smugmug.com/All/i-pQQvDML/0/635bc910/Th/KLRunder35W-Th.jpg) (https://fotoguzzi.smugmug.com/All/i-pQQvDML/A)
I've had a number of KLR's including the Barbie color, DR a better bike.
Title: Re: Explosion in a KLR factory ngc
Post by: steven c on January 06, 2018, 06:50:09 PM
 Nice. I have had the KLR and really liked it,would like to try the DR650 if one came up for the right price.
Title: Re: Explosion in a KLR factory ngc
Post by: normzone on January 06, 2018, 09:17:00 PM
Damn ....

I looked at all of that closely, and I'm completely at a loss for a smart-ass comment here.

Please select one of my other comments from somewhere else and consider using it here also.

We thank you for your continued support.
Title: Re: Explosion in a KLR factory ngc
Post by: nc43bsa on January 06, 2018, 09:47:16 PM
That looks like enough parts to assemble 3 engines.   :evil:
Title: Re: Explosion in a KLR factory ngc
Post by: Guzzi Gal on January 06, 2018, 10:42:31 PM
RUN AWAY!  RUN AWAY!  :evil:
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 07, 2018, 09:30:35 AM
That looks like enough parts to assemble 3 engines.   :evil:

I've gotta agree. There are just two, though. He had a leaking water jacket on the original engine, and sourced another for the cylinder, etc. Tore it all down when I was out in SoCal, and is waiting for parts.
I went out and had a quick look when I returned home, and texted him.. "Have you noticed that rod small end bushing?"  :cool: :smiley:
Gimme a Guzzi. That thing is full of chains and leevers..  :evil: :smiley:
Title: Re: Explosion in a KLR factory ngc
Post by: webmost on January 07, 2018, 09:36:38 AM
Delicious. What better to do over a winter like this one.
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 07, 2018, 09:46:17 AM
Delicious. What better to do over a winter like this one.

Well, there is that.  :smiley: However, I was sort of intending on playing with *my* stuff instead of having this (ahem) POS scattered all over the shop.  :grin:
Title: Re: Explosion in a KLR factory ngc
Post by: webmost on January 07, 2018, 09:55:28 AM
Delicious. What better to do over a winter like this one.

Give the boy some room, he'll soon put together his own shop. Best thing you could ever do for the young man. Then you can go over there and drink beer with him.
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 07, 2018, 10:31:33 AM
Give the boy some room, he'll soon put together his own shop. Best thing you could ever do for the young man. Then you can go over there and drink beer with him.

I've always enjoyed mentoring kids.. although he was pushing it a little when his Ducati broke down on the way to the Wisconsin Guzzi rally and he wanted me to come pick him and his bike up. In the middle of the night.  :smiley:
Title: Re: Explosion in a KLR factory ngc
Post by: twowings on January 07, 2018, 10:53:30 AM
And then you get to the rally and there is a torn-down Norge scattered across the camping area... :rolleyes:
Title: Re: Explosion in a KLR factory ngc
Post by: Lee Bruns on January 07, 2018, 11:29:53 AM
shoulda got a DR  ?

(https://photos.smugmug.com/DR-650/i-GFM9TTb/0/a5ed698b/L/IMG_2002-L.jpg) (https://fotoguzzi.smugmug.com/DR-650/i-GFM9TTb/A)

(https://photos.smugmug.com/All/i-pQQvDML/0/635bc910/Th/KLRunder35W-Th.jpg) (https://fotoguzzi.smugmug.com/All/i-pQQvDML/A)
I've had a number of KLR's including the Barbie color, DR a better bike.

Yep. DR has so many design advantages it is so very odd that it doesn't outsell the KLR. Peer pressure is a powerful thing.
Title: Re: Explosion in a KLR factory ngc
Post by: normzone on January 07, 2018, 11:47:11 AM
I've always enjoyed mentoring kids.. although he was pushing it a little when his Ducati broke down on the way to the Wisconsin Guzzi rally and he wanted me to come pick him and his bike up. In the middle of the night.  :smiley:

Childless by choice, myself, so everything I know about child raising is second hand at best, but as I understand it they grow up somewhere around 35.

Or not. YMMV.

I'm glad to learn that there's more than one engine in that pic. I was trying to put it all back together in my mind and I got a headache.
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 07, 2018, 07:50:42 PM
And then you get to the rally and there is a torn-down Norge scattered across the camping area... :rolleyes:

It must have stressed that guy out getting it all back together. After that, every time I saw him, he had beer in hand sitting and guarding the beer wagon.. <shrug>  :smiley:
Title: Re: Explosion in a KLR factory ngc
Post by: twowings on January 07, 2018, 07:52:05 PM
"They also serve, who only sit and drink..."
Title: Re: Explosion in a KLR factory ngc
Post by: Darren Williams on January 08, 2018, 03:40:06 PM
Yep. DR has so many design advantages it is so very odd that it doesn't outsell the KLR. Peer pressure is a powerful thing.

I've owned one DR and later two KLR's.  The KLR had better road manners, but way too many other issues when compared to the DR. If I was to get another it would be a DR hands down. By the time you are done modifying them, costs will be about the same with the DR a little less.

I think there is some powerful KLR Kool-aide out there, almost as powerful as BMW's.  When it comes to common man motorcycles, Suzuki has a few that are really in the sweet spot. Bandit, V-Strom, and DR. In my opinion of course.
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 08, 2018, 03:59:02 PM
Quote
I think there is some powerful KLR Kool-aide out there, almost as powerful as BMW's. 

Ahhh. That explains it. His mom and stepdad both have Beemers.  :evil:
Honestly, I don't have a dawg in this fight, but I'm not terribly impressed with the KLR either. It'll be a good learning experience for him, though..
Title: Re: Explosion in a KLR factory ngc
Post by: trippah on January 08, 2018, 04:06:06 PM
What I think I would learn from this is the metal scrap dealer's phone number. :grin:

Title: Re: Explosion in a KLR factory ngc
Post by: Groover on January 08, 2018, 04:24:17 PM
My heart skipped a beat for a second.. looked like one of my favorite 80's Enduros that I could never get my hands on back then; 1989 Yamaha 600 XT in green and purple.


(http://thumb.ibb.co/esdSp6/Yamah_XT_600_1989.jpg) (http://ibb.co/esdSp6)




Title: Re: Explosion in a KLR factory ngc
Post by: Lesman on January 09, 2018, 10:41:08 AM
I rode a 2014 DR650  last Sunday. It was extremely gutless. I had a brand new XL500 in 1980. I weighed 145lbs in 1980. It seemed twice as fast and responsive as the DR650.  You can't believe how disappointed I was when I rode the DR650. I really thought I was going to get one at some point down the road. I weigh 210 now. My buddy weighs 225 and 6'2". He wants to ride to Costa Rica on it . I see maybe at best,  Houston to Corpus Christi before he turns around.
My XL 500 would do throttle only wheelies in the 1st and 2nd. It had a top speed of way over 80. ( I can't remember if it had 80mph or a 100 mph speedo). Got 60+ mpg possibly more. It had the brakes of a Honda 90.
Title: Re: Explosion in a KLR factory ngc
Post by: Groover on January 09, 2018, 11:25:16 AM
I had a 1986 Honda 600 XL-RM (smaller tank than the XL), and a few of my friends had 1988 DR650s (one of them unfortunately died in an accident racing it). I thought the DR's were "tighter" and more hyper overall, whereas the Honda was more relaxed. I put a 1-tooth smaller front sprocket and made a world of difference in the performance, which I liked better for my use.
Title: Re: Explosion in a KLR factory ngc
Post by: twowheeladdict on January 09, 2018, 12:42:22 PM
I really enjoyed my '08 KLR 650.  I bought it with 2000 miles on it and $4000 in upgrades from a doctor who was setting it up for an Alaskan adventure and then realized he couldn't break away from his 70 hour work schedule.

It had all the 'fixes' done when new, as well as top notch suspension and all the nice protection and luggage. 

I just didn't feel like the bike was happy when running beyond 65 mph and ended up replacing it with the Versys 650 and a KLX250S. 

I sold it to my next door neighbor and he commuted 100 miles a day on it.  He was over 50,000 miles when a texting teen jumped out in front of him.


(http://thumb.ibb.co/bEOU46/DSCN1307a.jpg) (http://ibb.co/bEOU46)

(http://thumb.ibb.co/jU42P6/DSCN1330a.jpg) (http://ibb.co/jU42P6)

(http://thumb.ibb.co/hZ6tWm/DSCN3998.jpg) (http://ibb.co/hZ6tWm)



Title: Re: Explosion in a KLR factory ngc
Post by: Darren Williams on January 09, 2018, 12:57:51 PM
$4000 in upgrade? Wow, I didn't know there was that much you could do to a KLR.  Maybe that's why I never really bonded with mine.
Title: Re: Explosion in a KLR factory ngc
Post by: canuck750 on January 09, 2018, 01:00:27 PM
Between my two sons and myself we own 3 KLR's, best bang for the buck bike I have ever owned.
We have put a fair chunk of miles on them and they are pretty reliable other than the rock that shattered the oil sight glass a couple hours east of Phoenix two years ago, no that was an expensive fix! Amazing what a total loss of oil can do at 70 mph on a hot day, the top end basically melted.
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 09, 2018, 02:17:32 PM
Austin has been traveling on business and *fortunately* hasn't had time to go farther on this project. He's coming tonight to get a lesson in reality.   :smiley:
I've mentioned before that the cheapest motorcycle you can buy can be the most expensive? Oh yeah, this thread.
Of course, he saw this
(https://farm5.staticflickr.com/4612/38704533405_7c3d27cd66_c.jpg) (https://flic.kr/p/21YbRkt)2018-01-09_02-51-39 (https://flic.kr/p/21YbRkt) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
and thought, "No problem, I'll just switch heads and cylinders with the spare engine and be good to go.." Ordered a gasket set and carb rebuild kit.  :grin:
He didn't realize he was looking at a classic case of oil starvation..
Simple KLR engine for your viewing pleasure..  :shocked:
(https://farm5.staticflickr.com/4607/24732847407_9585a198c1_c.jpg) (https://flic.kr/p/DFyiRz)2018-01-09_02-53-12 (https://flic.kr/p/DFyiRz) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
The first time I went out in the shop and saw the cam, I walked over to the bike and had a look at the rod.
Didn't need to get out my mics and telescope gauges to see the small end, and no doubt the big end rod bearings are junk..
(https://farm5.staticflickr.com/4767/24732868387_a4487f642b_c.jpg) (https://flic.kr/p/DFyq6i)2018-01-09_02-54-18 (https://flic.kr/p/DFyq6i) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Tonight.. he will learn about how oil travels through the engine and how to use telescope gauges.  :smiley:
Maybe all is not lost. I checked the small end bushing on his spare engine, and it has .001" clearance. I don't know what they specify, but that's probably in the ball park.
It's no doubt been ridden hard and put away wet, though. Check out the countershaft sprocket on the "good" engine.
(https://farm5.staticflickr.com/4670/39600500131_7690a03bba_c.jpg) (https://flic.kr/p/23kmV2D)2018-01-09_02-55-06 (https://flic.kr/p/23kmV2D) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Experience is a tough teacher. She gives you the test first, then the lesson.  :wink: I'll mention that to him..
I'll get him on a Guzzi yet.
Title: Re: Explosion in a KLR factory ngc
Post by: Darren Williams on January 09, 2018, 03:47:55 PM
Older KLR's had a bit of a problem with oil burners, almost from new. My 2006 would get oil every gas stop and sometimes between them (it had a big tank so lots of range). Lots of guys would let them get low on oil if not checked regularly.
Title: Re: Explosion in a KLR factory ngc
Post by: Antietam Classic Cycle on January 09, 2018, 03:54:06 PM
Older KLR's had a bit of a problem with oil burners, almost from new. My 2006 would get oil every gas stop and sometimes between them (it had a big tank so lots of range). Lots of guys would let them get low on oil if not checked regularly.

My buddy Carl's is a 2002 bought for $2200 when it only had 1400 miles on it. It now has over 50k miles on it and according to him doesn't use any oil between changes. He does take very good care of all of his vehicles though.

The only habitual oil burners I heard of were those around '09(?).
Title: Re: Explosion in a KLR factory ngc
Post by: canuck750 on January 09, 2018, 05:32:21 PM
Older KLR's had a bit of a problem with oil burners, almost from new. My 2006 would get oil every gas stop and sometimes between them (it had a big tank so lots of range). Lots of guys would let them get low on oil if not checked regularly.

2008 and 2009 reportedly had a problem with oil consumption, my 2008 is a burner and my other ones will go all year without loosing oil.
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 10, 2018, 12:36:17 PM
2008 and 2009 reportedly had a problem with oil consumption, my 2008 is a burner and my other ones will go all year without loosing oil.

I told Austin this, and he just looked at me and said, "Yeah, its an 08." The spare has a cam bearing problem.. but he said he could find another top end. He now understands much better how these things work, and is getting better at precision measurement, but he's not there, yet..  :smiley:
Title: Re: Explosion in a KLR factory ngc
Post by: webmost on January 10, 2018, 05:37:10 PM
I told Austin this, and he just looked at me and said, "Yeah, its an 08." The spare has a cam bearing problem.. but he said he could find another top end. He now understands much better how these things work, and is getting better at precision measurement, but he's not there, yet..  :smiley:

Ewww. What I heard, a batch of 08s & 09s got bored out of round.
Title: Re: Explosion in a KLR factory ngc
Post by: twowheeladdict on January 10, 2018, 06:57:26 PM
$4000 in upgrade? Wow, I didn't know there was that much you could do to a KLR.  Maybe that's why I never really bonded with mine.

Pretty easy to do with any bike.

New suspension front and back
Fork Brace
Engine Guards
HID Headlights
Skid Plate
KLX650 carb jets
Caribou Luggage system
Thermobob
Doohicky upgrade
rear brake reservoir guard

and I am sure many other things I have forgotten about.  The suspension has spoiled me for all other bikes.  I just can't bring myself to replace functioning suspension even if it isn't superior.  Don't keep a bike long enough to justify. 
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 10, 2018, 08:15:36 PM
Ewww. What I heard, a batch of 08s & 09s got bored out of round.

Thanks. I'll show Austin how to check for that tomorrow.
Title: Re: Explosion in a KLR factory ngc
Post by: Bluerobotz on January 11, 2018, 07:08:49 AM
KLR for sale , all of the hard work done , only needs the carb cleaned .

 Dusty

LOL ^^
Title: Re: Explosion in a KLR factory ngc
Post by: 73eldorado on January 11, 2018, 09:25:56 AM
The KLR’s that come to my shop blown up have one thing in common, ran out of oil and seized up. I have one customer that commutes 140 KM per day and has 60000 km on the bike. I’ve had to rebuild his rear shock but other than that it’s been a reliable bike. Regular maintenance is the key with all things mechanical.


Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 11, 2018, 10:21:43 AM
Quote
Regular maintenance is the key with all things mechanical.
Absolutely. And, with Guzzis.. electrical.  :smiley:
Good news for Austin.. here's what we found.
This is my antique (naturally) <shrug>cylinder bore gauge.
 (https://farm5.staticflickr.com/4651/25761853278_53aa1897d5_c.jpg) (https://flic.kr/p/Ffues7)2018-01-11_11-04-21 (https://flic.kr/p/Ffues7) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
The idea is to set your micrometer at the new dimension of the cylinder and zero the indicator. There is a little skill in doing this operation, but Austin picked it up easily.
Insert the gauge and hold pressure against the cylinder wall. The gauge keeps itself perpendicular to the cylinder bore.
Checks new in this direction..
(https://farm5.staticflickr.com/4746/24764990737_79a662851c_c.jpg) (https://flic.kr/p/DJp3WV)2018-01-11_11-04-48 (https://flic.kr/p/DJp3WV) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Shows .001" wear here.
(https://farm5.staticflickr.com/4744/39633260291_76680d738b_c.jpg) (https://flic.kr/p/23ofPtZ)2018-01-11_11-05-58 (https://flic.kr/p/23ofPtZ) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Total Indicator Reading (TIR) .002" in the worst place, well within service limits.  :thumb:
He has a good cylinder. Piston checks ok. I'll tell him to glaze break it, install new rings, and he'll be good to go.
Now, he needs to find a good head/cams.. there's one on the bay that nobody has bid on yet that looks good. I'm clueless as to where to find KLR stuff, so he's on his own.

Title: Re: Explosion in a KLR factory ngc
Post by: RinkRat II on January 11, 2018, 11:43:18 AM

 Lotta good Guy's and info here...https://www.klr650.net/forums/index.php?s=36b518b07727414d65c5ccddbdec36c8 (https://www.klr650.net/forums/index.php?s=36b518b07727414d65c5ccddbdec36c8)
  Sorta like Wildguzzi but their bikes are mostly Green..... :popcorn:

     Paul B :boozing:
Title: Re: Explosion in a KLR factory ngc
Post by: twowings on January 11, 2018, 11:52:33 AM
He's bonding with that bike, I can tell... :laugh:
Title: Re: Explosion in a KLR factory ngc
Post by: Darren Williams on January 11, 2018, 12:03:43 PM
Chuck, Eaglemike.com
Title: Re: Explosion in a KLR factory ngc
Post by: 73eldorado on January 11, 2018, 12:22:59 PM
Hey Darren are you talking about one those fire breathing neck twisting Eldorados or the Ambassabor!!
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 11, 2018, 12:40:58 PM
Chuck, Eaglemike.com

I'll see if he knows about them. A refurbished head with valve job, cams, etc. ready to go doesn't sound bad to me.
Thanks!
Title: Re: Explosion in a KLR factory ngc
Post by: Darren Williams on January 11, 2018, 12:43:10 PM
Hey Darren are you talking about one those fire breathing neck twisting Eldorados or the Ambassabor!!

Ya got the drop on me partner!  Actually I was referring to Eagle MFG and ENG, out in California. They sell lots of parts for KLRs.

Eagle Mfg & Eng
380 Vernon Ste D
El Cajon CA 92020
Title: Re: Explosion in a KLR factory ngc
Post by: Chuck in Indiana on January 11, 2018, 03:52:17 PM
Yeah, he knows about them. That's where he got his doohicky mod. He can't afford $650 on top of the $300 for the spare engine on top of the $1000 he originally gave for the "cheap" KLR.  :smiley: I mentioned that he probably can find a $300 head on the bay.. then spend how much? getting it ready to install.
What was that saying about the cheapest motorcycle you can buy?   :weiner: Live and learn.
At least it's a roller, and he can get it out of my shop so I can play Guzzi. He's learning a lot.. and actually thanked me today for keeping him out of trouble on this project.
Title: Re: Explosion in a KLR factory ngc
Post by: steven c on January 11, 2018, 06:53:07 PM
 I bought a boat like that once.