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Author Topic: All KLR owners: Please check! Update new KLR engine grenade!  (Read 8225 times)

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Offline lecap

All KLR owners: Please check! Update new KLR engine grenade!
« on: September 02, 2008, 06:29:27 pm »
NEW! If you have a new (2008 model and later) KLR650 please have a look at this thread:
http://www.wilddog.za.net/forum/index.php?topic=53004.0

The deep hole syndrome: Repair ten Gorillas. Prevention R40 and a few minutes of your time.





After at least one forum menbers KLR has expired from this mainetenance error and hints pointing towards the discarding of the oil filter bypass valve being more widespread than I thought...

Here's the whole story! Brutal facts!. All revealing pictures!

The oil filter bypass valve

It is supposed to open a bypass for the engine oil in case the oil filter is blocked or if the oil is so cold and thick (on a chilly morning in Sutherland) that it does not want to go through the filter.

It is a tubular assembly sitting inside the oil filter. It is sometimes discarded together with the old oil filter. Apparently even by trained mechanics and in Kawasaki workshops :o
The new filter will not do anything. After a while your KLR will expire with a broken big end bearing or main bearing.

Better go and check if you have only the slightest doubt if the bypass valve is in your engine:

If the bike has been parked overnight on its side stand you can open the oil filter without any mess as the oil will have drained into the sump. Remove the two 8mm hex bolts and carefully lever the filter cover out by inserting a screw driver / turning the cover / wiggling it out. Do not use force or you will break the cover.

You should find this:

The bypass valve assembly is clearly visible protruding out of the centre of the oil filter.

Compare with a picture of an oil filter where the bypass valve was removed:


If your oil filter bypass valve is missing do not ride the bike.
Order part number 16156-002 PISTON-ASSY. VALVE
from the next Kawasaki dealer and fit it into the oil filter with the end with the thinner diameter to the inside (The oil filter cover will not fit the other way around)

Fit the oil filter cover with the index mark pointing up. You will have to push the cover in a bit to reseat the o-ring seal. Tighten the 8mm hex bolts to 10Nm.

The check only takes a few minutes.
The bypass valve costs around R 100.
A complete engine rebuild will cost you around R 15000
« Last Edit: September 09, 2010, 10:43:44 am by lecap »
"If you think it's expensive to hire a professional to do the job, wait until you hire an amateur." (Red Adair)
 

Offline Fugly

Re: All KLR owners: Please check!
« Reply #1 on: September 02, 2008, 06:38:26 pm »
 :thumleft: maybe Rone can confirm how easy it is to throw this away???

Thanks Lecap!
Donít worry about things that arenít, worry about things that are and your decisions are so much easier to make!
 

shark_za

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Re: All KLR owners: Please check!
« Reply #2 on: September 02, 2008, 06:41:36 pm »
Why would this sieze the bike?
Just not let the oil filter work but the volume of oil in there is so small it will just fill up and drain out the bottom?
 

Offline Ronť

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Re: All KLR owners: Please check!
« Reply #3 on: September 02, 2008, 06:49:41 pm »
Why would this sieze the bike?
Just not let the oil filter work but the volume of oil in there is so small it will just fill up and drain out the bottom?


No working oil filter = broken bearings if I am not mistaken.  And yes I did throw mine away and luckely only rode around without it for 2 days, where after I had to go and dig it out the rubbish bin after Fugly mentioned reading about it some where.
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Offline Fugly

Re: All KLR owners: Please check!
« Reply #4 on: September 02, 2008, 06:57:08 pm »
No mechanic but blocked filter, no bypass no oil to crank??
Donít worry about things that arenít, worry about things that are and your decisions are so much easier to make!
 

Offline Maya_The_Bee

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Re: All KLR owners: Please check!
« Reply #5 on: September 02, 2008, 11:02:55 pm »
thanks for sharing Lecap  :thumleft:
 

Offline lecap

Re: All KLR owners: Please check!
« Reply #6 on: September 03, 2008, 09:14:56 am »
The oil goes straight through the centre of the filter without actually being filtered.
Means nothing happens immediately as the oil gets everywhere it's needed.
Trouble starts as soon as you have some particle in your oil that's too small to be caught by the mesh screen in the oil pump intake.
All the nasty stuff that normally ends up in the filter and is kept there until the next filter change is now circulated through the engine at high frequency.
The oil circuit splits into three branches after passing the filter:
The gearbox: Stuff that gets pumped through here will usually do little harm.
The cylinder head: Particles will get pumped into the camshaft journals and bucket barrels :o
Clearances between camshafts and journals and buckets and their barrels are in the range of 0.02mm to 0.05mm.
The crankshaft: A lot of oil flows through the crankshaft to cool and lubricate the main bearings and the big end bearing. The oil gets flung off the crank into the barrel to lubricate and cool the piston, small end journal, gudgeon pin & piston rings. Dirt will pit the bearing races and seize the piston. Pitting of the bearing races is as bad as it can get as every tiny particle coming off the races or rollers joins the vicious circle and turns it into a runaway chain reaction.

Obviously and nastily the poblem will develop very slowly and the engine might run for a very long time without symptoms but at some stage the right particle gets pumped into the right place and then it's quick quick to the scrapyard.
"If you think it's expensive to hire a professional to do the job, wait until you hire an amateur." (Red Adair)
 

Offline Fugly

Re: All KLR owners: Please check!
« Reply #7 on: September 03, 2008, 09:39:59 am »
 :thumleft: Thanks again!
Donít worry about things that arenít, worry about things that are and your decisions are so much easier to make!
 

Offline Captain Zef

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Re: All KLR owners: Please check!
« Reply #8 on: September 03, 2008, 10:00:50 am »
Thanks for the info Le Cap :thumleft:
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Offline LeonDude

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Re: All KLR owners: Please check!
« Reply #9 on: September 04, 2008, 09:45:50 pm »
Thanks, much appreciated.
Great news, my book 'Sniffer' has seen the light of day on Amazon Kindle!
https://www.amazon.com/dp/B01N664WIH
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Offline LeonDude

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Re: All KLR owners: Please check!
« Reply #10 on: September 05, 2008, 08:19:39 pm »
After some frantic calls to get hold of the valve I finally found one at Boksburg Kawa - Thanks Debbie.

Here's what the valve looks like.
Great news, my book 'Sniffer' has seen the light of day on Amazon Kindle!
https://www.amazon.com/dp/B01N664WIH
Check out my website for free short stories!
http://www.leondekock.com/short_stories.html
 

Offline Groenie

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Re: All KLR owners: Please check!
« Reply #11 on: September 05, 2008, 08:41:23 pm »
And it cost you how much?

You should go to everyone that serviced your bike and moer them. Sure, most will be innocent, but ONE deserves it!
« Last Edit: September 05, 2008, 08:41:49 pm by Groenie »
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Offline LeonDude

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Re: All KLR owners: Please check!
« Reply #12 on: September 05, 2008, 08:46:40 pm »
Cost R125. BTW, I ordered from Kawa lifestyle in centurion but they can only deliver on tuesday, so there's going to be one extra.

I'm pretty sure the bike came without one because I serviced it first and I'm pretty sure the bike never had one in, because in my curiosity I just about take things like old oil filters apart to check what they look like. (Visualize me covered in oil with a stoopid expresion on my face).

Great news, my book 'Sniffer' has seen the light of day on Amazon Kindle!
https://www.amazon.com/dp/B01N664WIH
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Offline Groenie

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Re: All KLR owners: Please check!
« Reply #13 on: September 05, 2008, 09:06:08 pm »
(Visualize me covered in oil with a stoopid expresion on my face).



As jy nie jou hande vuil kry nie, dan verdien jy nie 'n KLR nie. Maar ek weet hoe jy voel
Don't look back, that's not where you're going.
 

Offline roburt

Re: All KLR owners: Please check!
« Reply #14 on: September 08, 2008, 02:58:47 pm »
to make live easy


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Offline Ronť

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Re: All KLR owners: Please check!
« Reply #15 on: September 08, 2008, 08:29:41 pm »
Dankie baie f0&^%n dankie. As jy dit vroer ge-post het dan het ek nie nodig gehad om in die vuilgoed drom te gaan rond krap nie........
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Offline roxenz

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Re: All KLR owners: Please check!
« Reply #16 on: September 30, 2008, 04:51:08 pm »
Took me a week to scrunch up the courage, but I checked on Sunday...

... and it was there!   :hello2:
 

Adventure MX

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Re: All KLR owners: Please check!
« Reply #17 on: September 30, 2008, 07:18:33 pm »
Thanks for sharing lecap :mwink:
 

Offline Maverick2

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Re: All KLR owners: Please check!
« Reply #18 on: October 09, 2008, 09:58:21 am »
Thanks Lecap
 

Offline Airborne

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Re: All KLR owners: Please check!
« Reply #19 on: October 09, 2008, 10:54:20 am »
 thanks  :thumleft: