lecap
Bachelor Dog
NEW! If you have a new (2008 model and later) KLR650 please have a look at this thread:
https://wilddog.net.za/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
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
https://wilddog.net.za/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
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
