As discussed in KLR 650 Restoration Part 1 and Part 2, I was forced to replace the entire top end after it suffered catastrophic internal damage that likely arose from oil starvation. I purchased and installed a largely intact 2013 top end that the vendor represented to have under 5,500 miles.
More problems identified and addressed:
Following my last report (KLR 650 Restoration Part 2) I ran into a big problem having found coolant in the oil. I noticed the frothy-white through the oil check window, which is an indication of significant moisture in the oil. That was over a month and a half ago.
After consulting with other KLRistas, we decided that the head gasket (which I did not replace in the top end replacement) most likely blew out. So I tore the whole thing apart...again...and replaced the head gasket. The problem persisted.
The only other source of coolant is the water pump, which has two seals, one on each side of the right case/clutch cover. The inner is a basic seal for the impeller shaft and the outer is a mechanical seal with a spring that opens and closes to relieve pressure through a weep hole on the bottom of the water pump. Well...when I got it apart, I found that the weep hole had been plugged...purposely.
Onward....
My attempt to rebuild the water pump failed twice, damaging two inner seals. That is one miserable item to replace. I finally gave in and got my dealer involved. After their inspection, they determined that that impeller shaft was bent. Crikey! Did I do that? Maybe, I don't know. However, I had them do the repair. So, more money than I wanted to spend, but we're good now.
On the coolant in the oil, there were a number of discussion threads around where owners tried to describe what the frothy mix looks like. The next two photos are the same drained fluid. The first photo is upon drain and the second photo is after a few minutes. Since oil floats on water, after a few minutes the mix of foamy oil-water separates with oil on top. There you go...
Ready for the trails:
Having decided to put the KLR650 back into action, starting at the Wild Bear (New Smyrna Beach) in a few weeks, I also added some additional items to the restoration:
Dunlop D606 DOT Knobbies, tubes and strips
Tusk Front Crash Guards (1)
Enduro Engineering Roll Chart
Eagle Mike Prevailing Torque Countershaft Nut
Fresh OE Brake Pads (front and rear)
Congrats on getting her back on two wheels. And Dunlop 606s to boot! I’m guessing you’re preparing for some cool offroad stuff. Ride safe.
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