Wilsons Sandbox

Posted: **Tue Jun 16, 2009 2:43 pm**

I was reading that the post 96 KLR can be safely bored .5mm I have been thinking the 685cc would be nice project over this Winter. The piston is 102.5mm in the kit. How is this accomplished? Rick A17 [Non-text portions of this message have been removed]

Posted: **Wed Jun 17, 2009 5:17 am**

If you look at the OEM parts list for a KLR650, you'll see that there are 0.5mm over and 1.0mm oversized rings available. After that, you can 685 it. I don't know specifically what bore size the 685 kit requires but a local to me rider continues to receive good performance from his on a '08 KLR (second-hand oil-burner). He didn't mod his airbox, carb, or exhaust - all stock. MPG is still in the low 50s. Oil problem solved. I don't know if Schnitz offers an oversized set of rings if the 685 needs bored out. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, Rick McCauley wrote: > > I was reading that the post 96 KLR can be safely bored .5mm > I have been thinking the 685cc would be nice project over this Winter. > The piston is 102.5mm in the kit. How is this accomplished? > > Rick > A17 > > > > > [Non-text portions of this message have been removed] >

Posted: **Wed Jun 17, 2009 8:37 am**

Let me rephrase my question. I have a 2003. If the stock cylinder can be safely bored .5mm, this raises a red flag for me. The 685 kit requires the cylinder to be bored 2.5mm. How is it this is done without re-sleeving. Rick A17

--- On Tue, 6/16/09, Jeff Saline wrote: From: Jeff Saline Subject: Re: [DSN_KLR650] 685 kit To: ramachm12@... Date: Tuesday, June 16, 2009, 11:00 PM Rick, This is off list. Attached are two .jpgs of the cylinder boring set-up I used last winter. Plenty of meat on a post 95 cylinder (I think the cylinder has to be 96 or later) for the boring. I had a friend hone to size after I got the cylinder to within about 0.0030". I haven't had time to install the 685 kit but might get to it in a few weeks. I think for most folks that will only do this once the best bet is to use the Schnitz recommended shop and pay the bucks. This was in no way cost or time effective for me but it was a fun project. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT On Tue, 16 Jun 2009 12:42:53 -0700 (PDT) Rick McCauley writes: > I was reading that the post 96 KLR can be safely bored .5mm > I have been thinking the 685cc would be nice project over this > Winter. > The piston is 102.5mm in the kit. How is this accomplished? > > Rick > A17 ____________________________________________________________ Digital Photography - Click Now. http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTDvmS4GAoHx0lDq0vRKwhkAtwxdHXgt0HVTU3eJxp6aEKWHMqEVck/ [Non-text portions of this message have been removed]

Posted: **Wed Jun 17, 2009 10:21 am**

I have the very first 685. It has more than 20K miles on it with zero issues. It does not burn any oil. I am unaware of any failures of bikes with this excellent kit. It is possible that the availability of OEM oversize parts are limited by some factor other than concerns related to barrel integrity. One such potential factor might be simple economics. How many people are going to keep a bike long enough to require a third oversize ring kit? I suspect you will be delighted with the improvement that the 685 kit makes. From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of Rick McCauley Sent: Wednesday, June 17, 2009 6:38 AM To: dsn_klr650@yahoogroups.com Subject: Re: [DSN_KLR650] 685 kit Let me rephrase my question. I have a 2003. If the stock cylinder can be safely bored .5mm, this raises a red flag for me. The 685 kit requires the cylinder to be bored 2.5mm. How is it this is done without re-sleeving. Rick A17 --- On Tue, 6/16/09, Jeff Saline > wrote: From: Jeff Saline > Subject: Re: [DSN_KLR650] 685 kit To: ramachm12@... Date: Tuesday, June 16, 2009, 11:00 PM Rick, This is off list. Attached are two .jpgs of the cylinder boring set-up I used last winter. Plenty of meat on a post 95 cylinder (I think the cylinder has to be 96 or later) for the boring. I had a friend hone to size after I got the cylinder to within about 0.0030". I haven't had time to install the 685 kit but might get to it in a few weeks. I think for most folks that will only do this once the best bet is to use the Schnitz recommended shop and pay the bucks. This was in no way cost or time effective for me but it was a fun project. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT On Tue, 16 Jun 2009 12:42:53 -0700 (PDT) Rick McCauley > writes:

> I was reading that the post 96 KLR can be safely bored .5mm > I have been thinking the 685cc would be nice project over this > Winter. > The piston is 102.5mm in the kit. How is this accomplished? > > Rick > A17

__________________________________________________________ Digital Photography - Click Now. http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTDvmS4GAoHx0lDq0vRKwhkAtwx dHXgt0HVTU3eJxp6aEKWHMqEVck/ [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

Posted: **Wed Jun 17, 2009 7:20 pm**

On Wed, 17 Jun 2009 06:37:52 -0700 (PDT) Rick McCauley writes:

> Let me rephrase my question. I have a 2003. > If the stock cylinder can be safely bored .5mm, this raises a red > flag > for me. The 685 kit requires the cylinder to be bored 2.5mm. > How is it this is done without re-sleeving. > > Rick > A17

<><><><><><><><> <><><><><><><><> Rick, Where did you get the info that the KLR post 95 cylinder can "only" be safely bored 0.5mm? Resleeving is needed for the 705 kit. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________________________________________________________ Senior Dating Online. Click Now! http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTQbQWQZDNCQG9UQyspUDhkCool9iJm3aw580kRmJOIueHi8pCZOOs/

Posted: **Thu Jun 18, 2009 8:08 am**

Thank you. I would like to do the 685 mod, as long as it didn't hurt the KLR's dependability, or cost a fortune in machining. Rick A17

--- On Wed, 6/17/09, Spike55 wrote: From: Spike55 Subject: Re: 685 kit To: "Rick McCauley" Date: Wednesday, June 17, 2009, 6:06 PM Rick: Apparently, Kawi offers a 0.5mm oversiaze and a 1.0mm oversize set of rings that go with the stock piston. Maybe they would go higher if they offered a piston to match. It appears that the 2.5mm oversize bore required by the 685 kit can be handled by the stock cylinder. I've heard that the 705 kit does require a new sleeve. Don R100, A6F --- In DSN_KLR650@yahoogroups.com, Rick McCauley wrote: > > Let me rephrase my question. I have a 2003. > If the stock cylinder can be safely bored .5mm, this raises a red flag > for me. The 685 kit requires the cylinder to be bored 2.5mm. > How is it this is done without re-sleeving. > > Rick > A17 > > --- On Tue, 6/16/09, Jeff Saline wrote: > > > From: Jeff Saline > Subject: Re: [DSN_KLR650] 685 kit > To: ramachm12@... > Date: Tuesday, June 16, 2009, 11:00 PM > > > Rick, > > This is off list. > > Attached are two .jpgs of the cylinder boring set-up I used last winter. > Plenty of meat on a post 95 cylinder (I think the cylinder has to be 96 > or later) for the boring. I had a friend hone to size after I got the > cylinder to within about 0.0030". I haven't had time to install the 685 > kit but might get to it in a few weeks. > > I think for most folks that will only do this once the best bet is to use > the Schnitz recommended shop and pay the bucks. This was in no way cost > or time effective for me but it was a fun project. > > Best, > > Jeff Saline > ABC # 4412 South Dakota Airmarshal > Airheads Beemer Club www.airheads.org > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650, 79 R100RT > > On Tue, 16 Jun 2009 12:42:53 -0700 (PDT) Rick McCauley > writes: > > I was reading that the post 96 KLR can be safely bored .5mm > > I have been thinking the 685cc would be nice project over this > > Winter. > > The piston is 102.5mm in the kit. How is this accomplished? > > > > Rick > > A17 > ____________________________________________________________ > Digital Photography - Click Now. > http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTDvmS4GAoHx0lDq0vRKwhkAtwxdHXgt0HVTU3eJxp6aEKWHMqEVck/ > > > > > [Non-text portions of this message have been removed] > [Non-text portions of this message have been removed]

Posted: **Thu Jun 18, 2009 8:25 am**

http://www.topgunmotorcycles.com/Product_Pages/klrprod.html Rick A17

--- On Wed, 6/17/09, Jeff Saline wrote: From: Jeff Saline Subject: Re: [DSN_KLR650] 685 kit To: ramachm12@... Cc: dsn_klr650@yahoogroups.com Date: Wednesday, June 17, 2009, 7:17 PM Rick, Where did you get the info that the KLR post 95 cylinder can "only" be safely bored 0.5mm? Resleeving is needed for the 705 kit. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________________________________________________________ You're never too old to date. Senior Dating. Click Here. http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTQbQXbCVR33MlnRG7uPlY83GHF9NxYftbR1mqiqdpYind9vpC5AOk/ [Non-text portions of this message have been removed]

Posted: **Thu Jun 18, 2009 8:41 am**

On Thu, 18 Jun 2009 06:25:26 -0700 (PDT) Rick McCauley writes:

> > http://www.topgunmotorcycles.com/Product_Pages/klrprod.html > > Rick > A17

<><><><><><><> <><><><><><><> Rick, Thanks for the link. I think they are trying to covering their butts with the comment. A good shop is also needed to bore the cylinder large enough for the 685 kit. : ) Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________________________________________________________ Save on Moving Supplies. Click Here! http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTQdZEBEzcAHgPp3ZLduSZ9JQ6CiwQRUNFFZdIDCeUWxYkHWuEQgOc/

Posted: **Thu Jun 18, 2009 9:17 am**

In re-reading it, I believe you are right. They are covering their butts. Or just ensuring the potential customer that the .5mm boring needed for their product is completely safe. Rick A17 ______________________________________________________ Thanks for the link. I think they are trying to covering their butts with the comment. Best, Jeff Saline [Non-text portions of this message have been removed]

Posted: **Thu Jun 18, 2009 10:13 am**

--- In DSN_KLR650@yahoogroups.com, Rick McCauley wrote:

> > > http://www.topgunmotorcycles.com/Product_Pages/klrprod.html > > Rick > A17 >

Although the principals at that site have made some valuable contributions to KLR lore, they are notorious as a source of bad information. Anything you read there must be taken with a grain of salt. Another way to look at it is to consider them a source of idiosyncratic opinion, but not reliable advice.

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