KLR 650 Restoration Part 1

As discussed in my post Welcome Home.... KLR650, I reported that I re-purchased my 2016 KLR650 after selling it earlier in the year. Unfortunately, I bought it back with some fairly significant damage.

Since my first report, I've has some considerable luck finding used components to virtually replace the top end from eBay Vendors

My best find was an OEM Head Cover off a 2013 KLR. The OE prices for the cover, gasket, bolts and o-rings rolls up into a big number...$331! I got used cover in good condition with fewer dings than on the original for $30!

I also got a complete top end with valves and the cams off another 2013 KLR. The complete top end was $600 (the new OE price was over $1,000). Then I got both cams (intake and exhaust) off the same bike from the same vendor for $200 (the new OE price was $637).

Now, there was a compete top end with valves off a 2016 KLR available. I offered the vendor $600...then $650, but he held tight on his price at $900. Perhaps a little bit of a gamble going with the 2013; however, I wouldn't have paid the $900. Rather, if I really felt that I needed a newer head, I would have bought a new OE head for $100 more and switched the valves off my current head over. So it is what it is.

All in all, the used parts seem to be in good shape. There were a few missing components and parts, but so far I've been able to transfer them over from the damaged top end.

Onward...

Now that I have the parts, I've started tearing down the motorcycle in my shop. It's so hot this time of year that it's hard to keep the shop even close to cool...and I have an air conditioner in there.

Fortunately, I have a Service Manual for this model, which is very helpful in figuring out how to get to the parts your trying to replace. In this case, it seemed like half the motorcycle had to be disassembled just to take the cylinder head off...but I got there.

The head on the right is the damaged head. I was pleased that I found the head gasket on the damaged engine in fair shape when I pulled it off. That part is $45.

I was not pleased when I found that the spark plug in the new/used top end was the wrong size such that I couldn't get it out with a spark plug wrench. It was an NGK but I couldn't see the size before smashing the insulator. What a total pain in the ass it was getting that thing out. I'm going to be using a Champion to get started, such as in the photo, but you can see that the socket size of the incorrect plug was much bigger.

Anyway, that's where I am with it at the moment. It'll be quick to get the cylinder head back in and then as time consuming putting it back together as it was taking it apart. Of course, I'll need to set the timing and valve clearances before kicking it over.

A couple interesting observations, though.

There is a spare starter relay fuse in the bottom of the boot. That was probably somewhere in the owners manual, but I missed it.

Then, I found a little filter in the primary fuel line. Now I know something else to check if I have a fuel starvation issue.