I had read on klr650.net and on advrider.com that the 2008 KLRs burn oil for some reason or another. I had also read that Kawasaki fitted a larger piston ring for the 2009 models.
Assuming they had fixed the issue, I bought myself a 2009 KLR650. For the first 1500 miles, it didn't burn any oil. I was going easy on it, keeping the throttle below 4000 RPM for the first 600 miles, then below 6000 RPM for the next 400 miles. (per Kawasaki's break-in instructions)
Nevertheless, my KLR is now an oil-burner. On a recent 450 mile day to central Indiana and back, I went through a quart of oil on the expressway. At least I didn't burn my engine up, like
this poor sucker. On the above-mentioned fora, there are a couple theories. One theory runs that Kawasaki has used some cheap cylinder liner, that soon goes out of round. Once it becomes even slightly oval-shaped instead of round, oil of course gets by the piston rings.
The other theory is that the oil is "aspirated" out of the crankcase somehow.
Over the years, there have been several suggested modifications (as opposed to farkles) for the KLR650:
- 685cc big-bore kit
- "Doohickey" modification (cam chain tensioner)
- Thermo-Bob (bypass thermostat system, for more constant engine temperatures year-round)
- PCV (Positive Crankcase Ventilation) valve addition
Some folks have reported that the insertion of a $4 PCV valve in the crankcase ventilator hose was enough to stop the oil consumption. Others said that after several thousand miles, they burn oil anyway.
After exhaustive research, I have decided to install the
Schnitz 685cc big-bore kit. My good buddies at KLR650.net and advrider.com have all reported that this forged piston kit resolves the oil burning issue once and for all. Not only that, but it yields a 6 hp gain and some torque as well. It is going to involve a pretty extensive engine tear-down, but I'm game. After all, that was part of the reason I bought the KLR in the first place: it is friendly to home mechanics. Today, I called them up and ordered it. I spoke to Ryan Schnitz (son of owner) and Shana Schnitz (daughter of owner) in the process. The mother also works there. Very nice. Not only am I supporting an American company, but a proper Ma 'n Pa store! I'm pretty excited about that. They also carry a lot of the other
recommended mods for the KLRs.
Over the last couple of days, I have bought both the Kawasaki manual and the Clymer service manual. If you're shopping for service manuals, do not bother looking for the Clymer manual on ebay. It is over 100% more expensive than it can be found at other retailers.
I'll post more about the progress of KLR mechanical mods in the near future. I am going to the
Sport-touring.net regional meet in a couple weeks. I won't be starting the install until after then.