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:
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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 [ Ссылка ]
KLR 650 2001 Carburetor Flooding Issues I fix it here [ Ссылка ] by pulling a plug in the gas cap
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