Okay I finally got a bit of time to complete teardown of the KLR engine.
As expected the bearing on the right hand side of the output shaft is damaged.
Category Archives: KLR
Tonight I worked more toward tearing down the KLR powerplant.
So I started out by checking the valve clearances, all were okay. Then I beheaded it.
Well if I’m ever going to fix the KLR I’ll need to find out the extent of the problem.
The KLR is now almost as light as a KTM.
Six months later I cleared a spot in the garage and started poking into it a little:
Just as I thought, complete failure of countershaft bearing. Chain wasn’t too tight (I had actually checked it on the side of the road), I’m pretty anal about it being within Kawasaki spec.
Anyway engine has to come out. That LH case may be trash, I’m not sure if the case damage goes beyond the seal mating surface. If it’s just the seal mating surface I may be able to get away with building up epoxy to rebuild the area that a bearing ball exited from.
When I bought the KLR back in July Josh included the old tank shrouds with the bike. The only problem is they had been torn off a few times and were in pretty bad shape. This weekend I finally got around to mounting them back to the bike.
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