KLR 650 COMPLETE ALL STEPS ENGINE REBUILD TOP END NEW PISTON 2001 CYLINDER BORE TEAR DOWN VALVE JOB

This is a complete engine rebuild of the top end of a Kawasaki KLR 650 2001 with a full valve job, cylinder bore, and a new piston. I document each step in the process; I start out with a compression test and then start disassembling from there. Valve clearances and shims are checked and discussed. I had a mechanic buddy bore the piston jug for me and I ended cleaning up the valves and reusing those. It's a rewarding process, and it's nice to see it running well again. Lots of good info in here, I also used the Schnitz racing manual as an additional reference. Here are the links to that:
www.schnitzracing.com/manuals/...
www.schnitzracing.com/manuals/...
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Interesting enough I took on this project because the bike felt quite under powered, I couldn't get the bike to go over 65 mph. I didn't really care about the smoking so much. After reassembling everything and putting a new piston in the problem didn't go away. It was the mechanic that bored out the cylinder for me that alerted me to the real problem. The carburetor diaphragm had holes in it, I got a new one of those and damn this bike is running great again. I'm still glad I did the valves and piston.
I also have a video up from when I rebuilt the monoshock on this bike, here's the link to that • How to Rebuild a KLR M...
KLR 650 2001 Carburetor Flooding Issues I fix it here • KLR 2001 CARBURETOR FL... by pulling a plug in the gas cap
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[@victorlopez9477]

I just used this to swap my piston and jug. Never did engine work before. Thank god this exists. Thank you

[@MrEd6066]

I'm starting my "Boreing" journey soon. Thanks for this!

[@bend3rbot]

I just love how you got modern rock playing in the background and Stanley has cruisey jazz. Generational change

[@ShJX602]

Fellow Colorado resident, just picked up a KLR 650 and will be doing this in the near future. Thanks for the video! Subscribed.

[@longdaysandhardworkatramra8260]

Great video dude, doing my head gasket tomorrow and I don't feel like I'm going in blind now

[@otisagain6225]

Nice work, I sure all who watch the whole video, know they will have to do this someday!

[@ridethroughlifertl]

Great video. It's frustrating to install a cylinder over a new piston and rings, and even more so to record yourself doing it. I definitely appreciate it though! That piston ring compressor tool is usually for pistons that get installed from the top, like on a car engine. I'm sure you probably knew that, but maybe someone will wonder and read this. I'm a CO rider too!

[@fookyuunsa678]

Thank you.

[@lionelkiernan6801]

What a guy! thanks for the video man

[@elevate9545]

Hi Jesse, great video. You have encouraged me to open my dear KLR. Now subscribed and a like. Greetings from Chile.

[@dogsdvl]

Hey Jesse! Great video man. Hope we can get ride in together sometime in the future be it on snow or dirt roads!😜 🤙🏼

[@patrkbukly4240]

Well done.

[@3104thunderchild]

The Valve clearance changed because you lapped the valves, so what happened is the valve seats when you used the drill ate down the valve seat changing the clearances, so the Right EX that you measured up at 0.15 before you cleaned up the seats must have gone smaller right ? the 0.15 probably never went in. so had get new shims ?

[@serramesabill2160]

the reason the valve adjustment changes is because of the wear on the valve seats. so if you lap the valves it will change the the height of the valve stem. before you by new valve shims recheck the adjustment. Also, the oil burning is likely due to loose valve guides, valve guide seals, or rings. Has nothing to due with valve seats. Make sure you check cam adjuster and replace it with the new type. (doohicky)

[@Chuffin_ell]

The compression release HAS to be disabled. It’s a fruitless endeavor to test compression with 30-40% cylinder pressure escaping through the exhaust. 😕

[@phillippray9578]

That engine has an Exhaust valve Decompression cam thingy. Makes compression low at start up for easy cranking.

[@MrPepper312]

Good job, I know that was harder not having the bike up on a lift. How many miles on the bike and did you ever have problems with the doohicky. My 2023 KLR doohicky failed at 1400 miles and dealer covered the repaired under warrenty. Have you heard of the 685 kit.

[@ryangotsch3670]

Very cool video! Appreciate it

[@axelpeemoeller8127]

My KLR is also using up oil like crazy, did this solve your oil consumption issue?

[@sizzlean9459]

The best mechanics are half chemist. You can dissolve that carbon off the heads and valves in 1 minute and at max 5 minutes with Toluene. It's expensive these days thanks to some assholes on the bad side of chemistry considering it is a waste product of the refining business, well actually everything they sell us is a waste product but I digress. Next time leave the valves in pour some on the combustion side on warmed up metal, wait 3 minutes rinse and then turn it over and do the same to the entire intake and exhaust passages. Try not to freak out when you pour the liquid off and you have brand new polished looking perfectly clean metal with no need to remove valves. Don't let it sit any longer than necessary as toluene tries to dissolve just about anything but i've never seen it mess with the seals. It will save you so much time and you'll never do a job like that again without it, just remember it dissolves 75