nklr jennifer's lessons/cartman/supertrapp

[pete1965@pacbell.net]

Ok, my 1st post "Scraped foot pegs" was a joke, this is not. I am in the process of getting the valves done at the machine shop and brought my cylinder bore in as well. It appears that the previous owner (according to the machinest) let it sit for a while and as a result the cylinder wall was damaged. Most likely by the rings oxidizing against the cylinder wall. Anyways, the machine shop recommends boring to 1 size over, and as a result I need to get a new piston. Any recommendations on sources ? Also, the reason I took it apart was not only the copious amounts of blue smoke from the exhaust indicating ring wear (figured may as well get the valves done as well), but a distinct "tink" in time with the cylinder. I stop short of calling it a "knock" because it was not that severe. The kind of "tink" that makes you whack the breaks, pull over and say "oh shit, what the hell is that?". It did not manifest itself upon first starting, but about 5-10 seconds after it started. I assume it was piston slap due to severe ring (??) wear but am now questioning the clearance between the wrist pin and the upper part of the connecting rod as the source of the noise. The center of the wrist pin is .94420" (+/- .00005)and I will replace it with a new one, but wondering if the wrist pin / connecting rod clearance is out of spec, and if this is the case do I just light the thing on fire and buy another one, cause I'd rather do that than tear into the lower part of the motor. Quite honestly, I have never done it before, but am pretty sure I don't want to. Pete

[garagedoor79@hotmail.com]

> oxidizing against the cylinder wall. Anyways, the machine shop > recommends boring to 1 size over, and as a result I need to get a

new

> piston.

Can you bore out a KLR jug? As I understood it, the KLR uses nikasil sleeves, and you just buy a new sleeve based on the next size needed, with a matching oversize piston as well. No biggy either way, since I hope I'm ages away from having to think about a job like this. FWIW Karl

[Ted Palmer]

garagedoor79@... wrote: [...]

> Can you bore out a KLR jug?

A normal oversize amount, yes.

> As I understood it, the KLR uses nikasil > sleeves, and you just buy a new sleeve based on the next size needed, > with a matching oversize piston as well. No biggy either way, since > I hope I'm ages away from having to think about a job like this.

Only a normal ferrous wet sleeve in there, AFAIK. You could bore a 650 sleeve bigger than factory max, but then the factory doesn't make a piston bigger than 1mm oversize anyway, so that limits choices a bit. If someone really needs a much bigger bore (I'm considering going to 650 bore size in my KLR600) then the stock sleeve might get too thin, which could lead to bore flex, reduced gas sealing and possibly bore cracking from fataigue. A custom sleeve into a bored out block would be the only truly reliable way to go. The KLX650 series uses "Electrofusion" coating on their bore. The KLX650 shop manual even tells us how the coating is done: "Electrofusion is a steel-molybdenum manufacturing treatment of the cylinder bore. The process involves using high voltage to alternately explode thin high-carbon steel wires and thin molybdenum wires directly inside the aluminium cylinder bore." Bores that are nikasil'd or electrofusioned generally are not sleeved. These coatings are used to eliminate the sleeve by putting a hard surface directly on the alloy bore. Mister_T

[Claes Borovac]

Is not this only done on the R model, the competition version? Not the C model, the "road" version. Claes, a swede in Dublin. -----Original Message----- From: Ted Palmer [mailto:tedp@...] Sent: 23 March 2001 14:13 To: DSN_klr650@yahoogroups.com Subject: Re: [DSN_klr650] Re: Is it Junk or Not ? garagedoor79@... wrote: [...]

> Can you bore out a KLR jug?

A normal oversize amount, yes.

> As I understood it, the KLR uses nikasil > sleeves, and you just buy a new sleeve based on the next size needed, > with a matching oversize piston as well. No biggy either way, since > I hope I'm ages away from having to think about a job like this.

Only a normal ferrous wet sleeve in there, AFAIK. You could bore a 650 sleeve bigger than factory max, but then the factory doesn't make a piston bigger than 1mm oversize anyway, so that limits choices a bit. If someone really needs a much bigger bore (I'm considering going to 650 bore size in my KLR600) then the stock sleeve might get too thin, which could lead to bore flex, reduced gas sealing and possibly bore cracking from fataigue. A custom sleeve into a bored out block would be the only truly reliable way to go. The KLX650 series uses "Electrofusion" coating on their bore. The KLX650 shop manual even tells us how the coating is done: "Electrofusion is a steel-molybdenum manufacturing treatment of the cylinder bore. The process involves using high voltage to alternately explode thin high-carbon steel wires and thin molybdenum wires directly inside the aluminium cylinder bore." Bores that are nikasil'd or electrofusioned generally are not sleeved. These coatings are used to eliminate the sleeve by putting a hard surface directly on the alloy bore. Mister_T Visit the KLR650 archives at http://www.listquest.com/lq/search.html?ln=klr650 Support Dual Sport News... dsneditor@... Let's keep this list SPAM free! Visit our site at http://www.egroups.com/group/DSN_klr650 To unsubscribe from this group, send an email to: DSN_klr650-unsubscribe@egroups.com Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/

[Krgrife@aol.com]

In a message dated 3/23/01 5:25:20 AM Pacific Standard Time, garagedoor79@... writes: << Can you bore out a KLR jug? As I understood it, the KLR uses nikasil sleeves, and you just buy a new sleeve based on the next size needed, with a matching oversize piston as well. No biggy either way, since I hope I'm ages away from having to think about a job like this. >> No, it is not nikasil and can be bored. Kurt Grife

[Jerry Jackson]

Scott, coincidentally I just finished installing my Supertrapp. Check it out at: http://www.jcj.net/klr/supertrapp_ids2.htm Jerry in Deltona, FL -----Original Message----- From: InWoods13@... [mailto:InWoods13@...] Sent: Friday, March 23, 2001 6:18 PM To: DSN_klr650@yahoogroups.com Subject: Re: [DSN_klr650] Re: NKLR Jennifer's lessons/Cartman/Supertrapp My tweet's now loud and noticeable......the Supertrapp thread isn't exactly inspiring confidence in my planned fix. Anybody have a number, on the expected life of a new IDS2...or the EAR series? Thanks Scott A14 "thunderdog"