catastrophic engine failure klr650 (2005/a19) : case study/disc
Posted: Thu Apr 20, 2006 5:18 pm
Thanks for the tool...good words and all the help. And thanks to
everyone for the encouragement and words of wisdom.
At first it sounded like a new engine but after speaking again with
my brother and the dealer, it's more like the sum-of-the-parts = new
engine. We're still waiting for the parts list though. I'm
considering suggesting my brother open up a case with Kawa if for
nothing else have something on record.
Bad luck?? Maybe. Had this not happened I probably would be 20 lbs
heavier from all the fish tacos down in Baja, I wouldn't have time
to do other upgrades to my bike, encourage others to get this
potential disaster fixed (including my own!), share time with new
friends/folks on this forum, and spend time with family and friends
here in San Diego. I'm sincerely thankful this didn't happen in
Cabo! So net-net I actually gained.
I will keep everyone posted on directions taken with the dealer and
Kawa, and let everyone know the extent and success of the repair job
in the final update.
Best regards - Brian and Ron (my brother)
--- In DSN_KLR650@yahoogroups.com, "wannabsmooth1"
wrote:

the> > --- In DSN_KLR650@yahoogroups.com, "traderpro2003" > wrote: > > > > Update 2 > > > > Well so much for a rush job...seem warranty work simply goes on
We> > back burner. > > > > I went over to the dealer to get a first hand look at things.
days.> > hadn't heard anything from Alba Action(less?) Sports for a few
remove the> > My timing was perfect as they spent the entire day trying to
3"> > flywheel unsuccessfully with an 8" threaded tool vs. the quality
back home> > version Eagle Mike sells. I couldn't believe it. So I rode
drive> > and got my Eagle Mike tool and viola! in 2 minutes (15 mins to
area> > there and back) it was done and 5 other technicians swarmed the
it's> > like viewers for Heraldo's underground tombs! It's no wonder
we> > taken almost 2 weeks to get no where. Anyway, with the mag off,
case side> > were able to find the culprit. The spring had broken off the
the> > and must detached itself from the intake doohickey and land on
Kawasaki> > timing chain advancing it. All the valves were destroyed.
engine> > will be replacing the piston, cylinder, valves...basically a new
problem> > from the initial dealer comments. Seems Kawa knows there is a
of us> > but is ok paying for/warrantying the few that implode. The rest
remote> > will spend the money to upgrade to avoid breaking down on some
or> > trip I suppose... > > > > Cheers - Brian > > Brian, > > Thanks for the good words on the tool! > > Sorry it was so bad. If you can, get them to go as far as possible > into the engine to make sure all is good. Kawasaki does not stock
course> sell a complete replacement engine for the KLR650. > > Does this mean it's all not just another internet myth? And of
ever.> all the dealers are correct in telling us it's not a problem -
ok?> Oh, yeah, it was fixed last year - oops, I meant the year before > last....or whenever........ > > Sorry for your bad luck, man........ Let us know the final result,
> > all the best, > > Mike >