KLR 650 COMPLETE ALL STEPS ENGINE REBUILD TOP END NEW PISTON 2001 CYLINDER BORE TEAR DOWN VALVE JOB

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This is a complete engine rebuild of the top end of a Kawasaki KLR 650 2001 with a full valve job, cylinder bore, and a new piston. I document each step in the process; I start out with a compression test and then start disassembling from there. Valve clearances and shims are checked and discussed. I had a mechanic buddy bore the piston jug for me and I ended cleaning up the valves and reusing those. It's a rewarding process, and it's nice to see it running well again. Lots of good info in here, I also used the Schnitz racing manual as an additional reference. Here are the links to that:
www.schnitzraci...
www.schnitzraci...
Please subscribe, comment, or like if you can and if you want to support me monetarily to make future videos like this I'd greatly appreciate it, you can donate by clicking here. www.paypal.com...
Interesting enough I took on this project because the bike felt quite under powered, I couldn't get the bike to go over 65 mph. I didn't really care about the smoking so much. After reassembling everything and putting a new piston in the problem didn't go away. It was the mechanic that bored out the cylinder for me that alerted me to the real problem. The carburetor diaphragm had holes in it, I got a new one of those and damn this bike is running great again. I'm still glad I did the valves and piston.
I also have a video up from when I rebuilt the monoshock on this bike, here's the link to that • How to Rebuild a KLR M...
KLR 650 2001 Carburetor Flooding Issues I fix it here • KLR 2001 CARBURETOR FL... by pulling a plug in the gas cap
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You can also find me on facebook / jessekhoff
Or on Instagram / kublakhanhoff
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You can also check out my video and photography website for more work www.jessehoff.com

Опубликовано:

4 окт 2024

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Комментарии : 66

@victorlopez9477 5 месяцев назад

I just used this to swap my piston and jug. Never did engine work before. Thank god this exists. Thank you

@JesseHoff 5 месяцев назад

Nice of you to stay. Glad I could help.

@ShJX602 2 года назад

Fellow Colorado resident, just picked up a KLR 650 and will be doing this in the near future. Thanks for the video! Subscribed.

@MrEd6066 9 месяцев назад

I'm starting my "Boreing" journey soon. Thanks for this!

@JesseHoff 7 месяцев назад

A little boreing it is. :-)

@bend3rbot 3 года назад

I just love how you got modern rock playing in the background and Stanley has cruisey jazz. Generational change

@profservices3614 2 месяца назад

😮

@otisagain6225 2 года назад

Nice work, I sure all who watch the whole video, know they will have to do this someday!

@longdaysandhardworkatramra8260 6 месяцев назад

Great video dude, doing my head gasket tomorrow and I don't feel like I'm going in blind now

@fookyuunsa678 2 месяца назад

Thank you.

@elevate9545 3 года назад

Hi Jesse, great video. You have encouraged me to open my dear KLR. Now subscribed and a like. Greetings from Chile.

@JesseHoff 3 года назад

Excellent good luck man.

@lionelkiernan6801 4 года назад

What a guy! thanks for the video man

@ridethroughlifertl 3 года назад

Great video. It's frustrating to install a cylinder over a new piston and rings, and even more so to record yourself doing it. I definitely appreciate it though! That piston ring compressor tool is usually for pistons that get installed from the top, like on a car engine. I'm sure you probably knew that, but maybe someone will wonder and read this. I'm a CO rider too!

@F80__Los 3 года назад

What part of colorado?

@patrkbukly4240 4 года назад

Well done.

@dogsdvl 2 года назад

Hey Jesse! Great video man. Hope we can get ride in together sometime in the future be it on snow or dirt roads!😜 🤙🏼

@JesseHoff 2 года назад

Ya man, let's do it.

@ryangotsch3670 4 года назад

Very cool video! Appreciate it

@Chuffin_ell 4 года назад

The compression release HAS to be disabled. It’s a fruitless endeavor to test compression with 30-40% cylinder pressure escaping through the exhaust. 😕

@JesseHoff 2 года назад

I was rewatching the video a couple of days ago thinking about this, I didn't disable the compression release but still was able to see an increase in compression after putting in oil. I think for testing purposes the way I did it works. What do you think?

@3104thunderchild 3 года назад

The Valve clearance changed because you lapped the valves, so what happened is the valve seats when you used the drill ate down the valve seat changing the clearances, so the Right EX that you measured up at 0.15 before you cleaned up the seats must have gone smaller right ? the 0.15 probably never went in. so had get new shims ?

@phillippray9578 4 года назад

That engine has an Exhaust valve Decompression cam thingy. Makes compression low at start up for easy cranking.

@JesseHoff 4 года назад

I still don't think it should have been that low though. What do you think?

@phillippray9578 4 года назад

@@JesseHoff Surprised it would have run if it was that low. But they do seem to keep running no matter what happens to them. That'd be a KLR for ya.

@serramesabill2160 4 года назад

the reason the valve adjustment changes is because of the wear on the valve seats. so if you lap the valves it will change the the height of the valve stem. before you by new valve shims recheck the adjustment. Also, the oil burning is likely due to loose valve guides, valve guide seals, or rings. Has nothing to due with valve seats. Make sure you check cam adjuster and replace it with the new type. (doohicky)

@paulbull3765 4 года назад

Thanks, was wondering what that was about. Appreciate your comment.

@thomasfx3190 2 года назад

Man I was you 25 years ago!

@slalomking Год назад

The valve clearances change because you lapped the valves.

@MrPepper312 10 месяцев назад

Good job, I know that was harder not having the bike up on a lift. How many miles on the bike and did you ever have problems with the doohicky. My 2023 KLR doohicky failed at 1400 miles and dealer covered the repaired under warrenty. Have you heard of the 685 kit.

@JesseHoff 10 месяцев назад

Got a little over 40K on it, no problems with the doohicky. I've heard of the 685 kit. Your right I need a lift :-)

@sizzlean9459 4 года назад

The best mechanics are half chemist. You can dissolve that carbon off the heads and valves in 1 minute and at max 5 minutes with Toluene. It's expensive these days thanks to some assholes on the bad side of chemistry considering it is a waste product of the refining business, well actually everything they sell us is a waste product but I digress. Next time leave the valves in pour some on the combustion side on warmed up metal, wait 3 minutes rinse and then turn it over and do the same to the entire intake and exhaust passages. Try not to freak out when you pour the liquid off and you have brand new polished looking perfectly clean metal with no need to remove valves. Don't let it sit any longer than necessary as toluene tries to dissolve just about anything but i've never seen it mess with the seals. It will save you so much time and you'll never do a job like that again without it, just remember it dissolves 75 5 of plastic chemiistry wares and it evaporates about as quick as anything besides ether leaving a coating behind of whatever it dissolved which can be a nightmare if it happens in the carb so it has it's purpose just don't think it is universal and you'll be fine. You can actually win plenty of money betting others who think they know everything about carbon and how to remove it, just don't expect them to smile when you take their money and they see how perfect the finish is compared to any other method up to glass blasting

@axelpeemoeller8127 8 месяцев назад

My KLR is also using up oil like crazy, did this solve your oil consumption issue?

@JesseHoff 7 месяцев назад

It did.

@williamahrens9560 3 года назад

Would be good to know how many miles are on bike.

@JesseHoff 3 года назад

40,000 miles :-).

@seanhammon6639 9 месяцев назад

Cool. Yeah, the valve lapping would have thrown out all the valve measurements. Did you rebore oversize and then fit an oversize piston? ... You were very lucky not to break that choke lug!

@wakandaforever5033 Год назад

My valves stuck on open

@alanreilly9056 3 года назад

Hi Jesse, I live in Australia and watch all of your video with great interest, however, seemed like at times you could have done with an extra hand or two?, but great job by yourself

@JesseHoff 3 года назад

Thanks man, a second hand would definitely be beneficial at times. :-) thanks for watching.

@jeironamobey8136 7 месяцев назад

Do you have to bore the engine to put piston rings in? My bike smokes on startup and started smelling like burning oil and oil comes out the cylinder exhaust. I plan on just putting piston rings in.

@JesseHoff 7 месяцев назад

I don't think you have to, throw new rings in and see what happens.

@666LudaH 4 года назад

thanks for nice video, how was the mileage?Have you seen oil burn?

@JesseHoff 4 года назад

37,000 miles on it, I've put about 1000 miles on it since the rebuild, no oil burn as of yet :-)

@allenbrandon1031 3 года назад

I was told to take the head off I needed to lock it at top dead center. Is that a thing and if so how do you do it?

@JesseHoff 3 года назад

Minute 10:46 I talk about that, definitely a thing.

@allenbrandon1031 3 года назад

@@JesseHoff how do you lock it once it’s at top dead center? Does it stay locked there or is there something you need to do to it?

@JesseHoff 3 года назад

@@allenbrandon1031 you don't have to lock it, it just stays there, there's no mechanism that locks it into place

@jasonmartin9001 Год назад

Where did you get piston rings?

@thekeygod9810 4 года назад

Whats that tool you used at 2:06 ??

@JesseHoff 4 года назад

It was a called a power driver, :-) I don't think they even make it anymore.

@jesseperedo6764 3 года назад

I have a question for you. Can a 2008 klr650 head assy fit and work on a 2008 klr650? Can the oil supply tube be modified to make it work?

@JesseHoff 3 года назад

Not sure man, seems like your asking about the same bike? 2008 is when the started changing things though. en.wikipedia.org/wiki/Kawasaki_KLR650 Find out and make a video about it. :-)

@jesseperedo6764 3 года назад

@@JesseHoff Im sorry. I meant 2011 vs 2007

@chrishoesing5455 3 года назад

I'm not trying to be a jerk, or make fun, think more like letting you know you have food on your face... That fuel valve is called a petcock, not a peacock. Unless your just joking, then never mind. Actually I kind of like it..lol, I might start using it.

@JesseHoff 3 года назад

It just sounds like that :-)