KLX650R Reliability????

[OldnDirty]

I have posted this here (and not the kawasaki forum) to get as wide a feedback as possible. I have also posted it to Thumpertalk. I am really interested to find out if my problems are inherit faults or if I'm been the victim of a comedy of errors.

I have had an ongoing reliability problem with my KLX650R. I would like to run the following past you all. I would like to know if I’m just the unluckiest KLXR owner of all time or are these bikes/engines just an unreliable ‘dog’?

The KLXR is an ’98 model. In this time it has completed a magnificent 5,000 miles. It has been out of service 6 times in that time/distance. Thrice for excessive oil consumption (new pistons and rings each time) and thrice for defective Auto Decomp (new cams each time). And now it has seized something (I haven’t taken apart the engine yet) in the cam chain assemble (probably the idle wheel) during a test ride (by a Kawasaki mechanic) after a replacement cam was put in. Some of the work has been under warranty and all the work has been done by Kawasaki dealers.

I’m asking the question because I don’t know if I should persevere with this ‘dog’. A guess would be I’m up for two new valves, an idle wheel assm, and all cam chains (the cam chains have jumped and striped the idle wheel – both or just one I don’t know but I assume the worst). If I was to do anything with this motor I would be pulling it right apart including the bottom end. I don’t suspect the bottom end but I would be checking and thoroughly cleaning. If the broader experience is that these things are unreliable ‘dogs’ I’ll give up and part it out for what I can get.

So guys, what your experience? Give it to me both barrels. I don’t care if you relate your personal experience or some else’s (but lets keep it reasonable). Be as specific as you can please.


Thanking you in anticipation,

Cheers, OldnDirty.

 

[xr650john]

WOW! You're having a tuff time. I have to say I really don't know much about the inherent problems with those bikes but it sure sounds like a lubrication problem to me. Are you using the proper oil and has the oil pressure/volume/and pump been phsyically checked? Just a thought but it sounds like lack of oil to the top end. Good luck!

 

[garrism]

I had a 1996 KLX 650R that I rode on trails with my son. It was a perfect bike and I would still have it if it werent for the weight. The bike never seemed to have any problems I rode and rode with just oil changes and filter cleanings. I am sorry that yours is having so many problems but everyone I knew that had one had good service with it.

 

[cujet]

Yes those cams are known to have spring and actuator problems.

It can be easily fixed in the backyard using a torch. Heat the compression release pin to a cherry red and bend it out. Install new springs.

In addition the counterbalancer chain uses a spring loaded adjuster. The spring sometimes breaks off and the adjuster will not tension the balancer chain. I used to pull the side case off and manually adjust the chain, then safety wire the adjuster without a spring. I also had a bolt back out internally and catch on a rotating part. Of course the bolt broke right off and got caught up in the works. I really cannot remember what the bolt was for. however that fix was easy too, remove the broken bolt and parts, replace and locktite bolt.


Those engines can be tempermental, My piston cracked between the rings. I replaced the piston and rings, problem solved for about 7K miles.

I even lost the waterpump shaft (balancer shaft) at the impeller. It just broke right off. So rather than replace the shaft (which took 9 months to get) I just welded in a new 6 mm bolt in place of the broken impeller shaft. It worked great.

All this kinda seems cheezy when you think about it, however If I had to wait for parts, I would never have had a running bike.

Chris