[dsn_klr650] cylinder out of round...
Posted: Thu Apr 09, 2009 7:12 am
				
				[[ My question is about the out of round cylinder. Did something happen to
 cause this, or is it a factory defect? ]]
 
 
 I doubt your cylinder was "out of round" the aluminum piston will worp before the steel cylinder.  Excessive heat will cause the piston to fail. Your lucky it is still under warrenty. if your running 5k+ RPM's . You should be using synthetic engine oil.  Plus, not sure what fuel you feed your engine, but 91 Octane is required.
 
 -Mike-
 
  
 
 
 ----- Forwarded Message ----
 From: Don Pendergraft 
 To: DSN_KLR650@yahoogroups.com
 Sent: Wednesday, April 8, 2009 7:55:59 PM
 Subject: [DSN_KLR650] Cylinder out of round...
 
 
 
 
 
 I have an '08 KLR that is a real oil burner. 1 quart every 500 miles like
 clockwork. I ascribed it to bad luck and the fact that I spend alot of time
 above 5K rpm's on the highway. The bike has about 16K miles on it. Anyway, I
 brought it to the dealership to get the recall work done (3 recalls) because
 I'm tired of getting the notices. I had also batched together a list of
 other things for them to fix/replace (e.g. rotted rubber giblets, KACR
 issue, lower high beam, etc). Lastly, I told them that I wanted to file a
 warranty claim on the oil consumption issue. I've known about it forever
 since I was an early adopter of the '08 (purchased July '07), but I figured
 the pioneers get the arrows and I I thought I should let others battle
 Kawasaki until things became clearer. Well, that strategy worked in that
 Kawasaki is well aware of the issue. So I brought in the bike...
 
 The mechanics were great. I even went to church with one of them. They said
 they would get it squared away for me. When they tore it apart, they said
 they could see where the oil has been blowing past the piston and that the
 cylinder looked like it was out of round. They contacted Kawasaki and got
 permission to bore the cylinder and go up to the next larger size. So they
 are ordering the new, larger, piston and rings. Kind of funny. I had no idea
 they had a slightly larger version. It's not the 685 kit, sadly! Just
 slightly bigger. The mechanics have a guy that does precision work on
 aircraft engines and they are going to let him do the boring. Anyway...
 
 My question is about the out of round cylinder. Did something happen to
 cause this, or is it a factory defect? My other thought was that band-aids
 like the 16T front sprocket would not have made a bit of difference. Anyway,
 bizarre about the cylinder. I'm hopeful that they can fix the problem. I'm
 about 50/50 on it I guess. Many have had the work done, with mixed results.
 The only sure fire way is to do the 685 kit. But I'm cheap. This isn't
 costing me a dime, so I will try it first. 
 
 Don+
 
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