Water pump seals

[Hoarserider]

Everything around the head stripped: exhaust, starter motor, radiator hoses, etc.

I thought I was good to go, but when I stepped up with a rubber mallet I guessed that the few bolts I saw (not mentioned in service manual) were going to keep that head on. Sure enough I found a thread about them: http://www.klr650.net/forums/showthread.php?t=53001.

I took out the allen key bolt but the others weren't so easy. Couldn't get a socket on and with a normal wrench (I call them spanners) the crown bolt heads started to strip. I've sprayed them with Wd-40 and left them overnight in the hopes that'll get in there (gravity not helping on these though so not super hopeful).

What can I use to get these off? If they strip I'm not in a happy place. I'd really hoped to get to the piston this evening so I could inspect and order parts accordingly but these two bolts have stumped me.

[Eaglemike]

Use a box end wrench. Be sure you are turning them the correct way - it's easy to get mixed up on those nuts. They are VERY tight if they've never been removed.

[Hoarserider]

I managed to get them off, but the heads are not looking pretty. I'll have to replace them.

So cyclinder head is off. The bottom of the valves look scorched. Carbon buildup all over them. The top of the piston also was blackened and had small hard bit on it, possibly metal shavings, possibly just clumps of carbon.

I'm going to take the valves out as at the very least they need a serious clean (sea foam?) and then I'll go for the piston.

[wymanwinn]

Originally Posted by Hoarserider

I managed to get them off, but the heads are not looking pretty. I'll have to replace them.

So cyclinder head is off. The bottom of the valves look scorched. Carbon buildup all over them. The top of the piston also was blackened and had small hard bit on it, possibly metal shavings, possibly just clumps of carbon.

I'm going to take the valves out as at the very least they need a serious clean (sea foam?) and then I'll go for the piston.

i would take the head to an automotive engine shop to do a valve job...money well spent IMHO...

you do have a manual...yes??? given your issues in taking the motor apart, i think you will need a bit more help putting it back together...

wyman

[wymanwinn]

BTW...when you do get to the cylinder, there is a 8mm headed bolt in the front/bottom of the cam chain tunnel...DO NOT LET IT DROP INTO THE MOTOR...

wyman

[Hoarserider]

Ha ha...thanks. Yeah, I noticed that one, by the front cam chain guard. I am sufficiently freaked out by the abyss. I stuffed some paper towel into the gap just in case but got that sucker out ok.

Cylinder is off and I think (hope) I have finally found my problem. It does look to be the piston. Major scoring on the front and back end. It looks like it partially seized, possibly as a result of the water pump failing (when I drained the radiator I got about two cups full of coolant. Odd as my temp gauge never skyrocketed). The cylinder is also scratched but it doesn't seem to be terrible. I'll post some pics in a second.

I'm pretty sure this is my prob but confirmations by more experienced hands will be a relief.

[Hoarserider]

Front of the piston. The back looks similar.



The cylinder. Its scratched but not too badly. How badly scratched does it have to be for a bore to be necessary? I'm hoping I can just get it honed and simply replace the piston.

[Hoarserider]

One of the rings seems stuck in the one side of the piston as well. Not surprising I guess.

[Eaglemike]

685 baby! You're gonna LOVE it!

[wymanwinn]

cylinder is toast...no hone will repair that...

like EagleMike says...685!!!

BTW...better focus on your images would help greatly...pull back a bit, your camera was too close...

wyman

[Hoarserider]

The cylinder did turn out to need a bore. It was marginal though, the guy I took it to thought I might be able to get away with a hone but after a proper inspection told me I'd need to bore. After a big of chatting to the Shwinn folks I decided to reign in the boy in me and pass on the 685. I've been delayed already for far too long, and the small chance I'd need to play with carb jets made me rule against it.

My delay has meant that my plans might shift enough to put me in San Diego for Xmas. Eaglemike, If I'm headed there I'll let you know so I can come pick up a doohickie and drop off some beer.

[wymanwinn]

curious here...if you bored and honed the cylinder, what piston did you use...???

wyman

[Hoarserider]

1mm oversize. I also decided that as I'm touring, I'd like to stick to keeping my gas mileage as high as possible. I did want that 685...it just didn't seem sensible for what I'm doing.