Explosion in a KLR factory ngc

[Chuck in Indiana]

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.   
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
2018-01-09_02-51-39 by Charles Stottlemyer, 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. 
He didn't realize he was looking at a classic case of oil starvation..
Simple KLR engine for your viewing pleasure.. 
2018-01-09_02-53-12 by Charles Stottlemyer, 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..
2018-01-09_02-54-18 by Charles Stottlemyer, on Flickr
Tonight.. he will learn about how oil travels through the engine and how to use telescope gauges. 
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.
2018-01-09_02-55-06 by Charles Stottlemyer, on Flickr
Experience is a tough teacher. She gives you the test first, then the lesson.  I'll mention that to him..
I'll get him on a Guzzi yet.

[Darren Williams]

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.

[Antietam Classic Cycle]

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(?).

[canuck750]

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.

[Chuck in Indiana]

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.. 

[webmost]

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.. 

Ewww. What I heard, a batch of 08s & 09s got bored out of round.

[twowheeladdict]

$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. 

[Chuck in Indiana]

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.

[Bluerobotz]

KLR for sale , all of the hard work done , only needs the carb cleaned .

 Dusty

LOL ^^

[73eldorado]

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.

[Chuck in Indiana]

Regular maintenance is the key with all things mechanical.

Absolutely. And, with Guzzis.. electrical. 
Good news for Austin.. here's what we found.
This is my antique (naturally) <shrug>cylinder bore gauge.
 2018-01-11_11-04-21 by Charles Stottlemyer, 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..
2018-01-11_11-04-48 by Charles Stottlemyer, on Flickr
Shows .001" wear here.
2018-01-11_11-05-58 by Charles Stottlemyer, on Flickr
Total Indicator Reading (TIR) .002" in the worst place, well within service limits. 
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.

[RinkRat II]

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

     Paul B

[twowings]

He's bonding with that bike, I can tell...

[Darren Williams]

Chuck, Eaglemike.com

[73eldorado]

Hey Darren are you talking about one those fire breathing neck twisting Eldorados or the Ambassabor!!

[Chuck in Indiana]

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!

[Darren Williams]

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

[Chuck in Indiana]

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.  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?    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.

[steven c]

 I bought a boat like that once.