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Old 06-02-2013, 04:13 PM   #21
Ten-guy
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Default Re: KLR650 Tengai project in the UK

Hi all,

Parts have been ordered today from Enduro Spares, ebay. Genuine gaskets ordered for this side of the motor too.

I have been busy polishing and painting what I have for now until I can get her running, then plan to strip again to powder coat the frame and paint the engine.

Bit disappointed, bought some metallic black high temperature engine paint from Halfords, which I used to paint the footrest hangers and rack. I cured this in the oven at 150C for 1/2 hour, but it is still soft, after 2 weeks curing. Rubbed it off with a rag on RH footrest hanger when I spilled some grease on it. This will be going back to the shop I may try and bill them for my wasted time . I am going to speak to my powder coater tomorrow and may put my funds towards a proper job instead.

Dismantled the water pump today, just about to order a seal for what it costs. There has definitely been water in the oil, so is either a result of this seal going, or the fact that the water pump hasn't been turning due to broken balancer and the engine has overheated at some time in the past - head gasket?

Here is a pic of the old girl after a days fiddling in the sun today. Still need the side panels, should have some fun finding them, and a couple of lugs snapped in the RHS fairing, a new one of these would be nice too.


Last edited by Ten-guy; 06-02-2013 at 04:15 PM.
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Old 06-05-2013, 01:55 AM   #22
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Default Re: KLR650 Tengai project in the UK

Halfords paint is never great chris. i like to use smaller motorist shops that have a better range than halfords own brand. for the footrest hangers / rack etc, i used alloy wheel paint then clearcoat and found that quite a durable finish. the small shops also do a paint called tough black which i've heard good reports on. Looking like a good project so far.
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Old 06-10-2013, 02:49 PM   #23
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Hi all,

Today has not been a very good one I think. I decided to delve into my clutch side of the engine to see what horrors lie within, while I wait for my balancer bits and EM doohickey.

Starting with the water pump, the mechanical seal was absolute toast. The PO had bunged up the weep hole allowing water to seep into the engine, on the bright side the head gasket may be OK.



Pulling the gauze thimble filter, I discovered where the rest of my tensioning spring and friction material from the chain guide had got to. The filter had actually imploded and it too was toast.



Now for the big fail. Correct me if I'm wrong, and please do correct me - but there appears to be a dirty great crack in the crankcase around the main bearing and balance shaft behind the water pump.



I now started to strip the bike to barebones while I wait for UK DVLA to make their mind up whether to give me a log book from the frame number. I cant powder this until I get the log book (title) just in case.



I will be quietly pulling the motor to pieces in the meantime with bum cheeks clenched.

If the right side of the engine is also toast. I was thinking of putting a C3 bottom end in it. The splines on the output shaft are worn anyway so was thinking that the C was a better design having a nut holding on the sprocket. Will this marry up to my earlier top end?

Last edited by Ten-guy; 06-10-2013 at 03:06 PM.
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Old 06-10-2013, 04:26 PM   #24
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Having my doo spring break, caused a bit valve damage. I took the opportunity to the 688. Hoping to get a chance to ride it before I move.
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Old 06-11-2013, 11:19 PM   #25
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subscribed in California

Looking forward to seeing what you do with this

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Old 06-17-2013, 03:57 AM   #26
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Default Re: KLR650 Tengai project in the UK

[quote=Ten-guy;1230501]
Now for the big fail. Correct me if I'm wrong, and please do correct me - but there appears to be a dirty great crack in the crankcase around the main bearing and balance shaft behind the water pump.



-------------
That there is a casting mark, we all have them, so no problem there...

as for the rest of it,

Srsly tho, I'd have given it a go too.
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Old 06-25-2013, 01:08 PM   #27
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Not been here for a while, got a new toy last week:



320 CDI

DVLA been in touch said they will inform me when they are coming to inspect the bike.

Last edited by Ten-guy; 06-25-2013 at 01:15 PM.
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Old 07-09-2013, 03:37 PM   #28
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Well folks, there is no record of this bike in the UK?

I have since written to Kawasaki (£54 later) who have confirmed that it is a December 1988, bike which is an earlier model than I thought.

Judging by the decals on it I now suspect that it is an import from Europe somewhere?
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Old 07-09-2013, 03:59 PM   #29
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It just gets better and better chris..lol.
Hope you don't get lumped with import duty when you try registering it.
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Old 07-09-2013, 04:17 PM   #30
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Quote:
Originally Posted by fat.col View Post
It just gets better and better chris..lol.
Hope you don't get lumped with import duty when you try registering it.
Oh sh!t didn't think of that
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Old 07-09-2013, 05:00 PM   #31
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Hopefully whoever brought it in had to pay that one....
How are you getting on with the engine?
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Old 07-09-2013, 05:54 PM   #32
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Default Re: KLR650 Tengai project in the UK

Dammit Col... why aren't you over there HELPING that poor man? You could be handing him cold beers and providing acerbic commentary!

That teeny island isn't THAT big... don't all you brits live within a couple miles of each other?

Get off the couch and go give your mate a hand!
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Old 07-10-2013, 01:33 AM   #33
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Your right robert. the united states of great britain is 3 1/2 miles wide and 6 miles long. i'll cycle over later with a few tins and a pocket full of cheery anecdotes to brighten up this project.
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Old 07-10-2013, 04:07 AM   #34
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E-mail from Kawi this morning - it is Italian

Colin - the bike is a rolling frame at the moment, engine main lump in the fame with both side covers off.

It is stuck behind my VFR at the minute as it is devoid of its back wheel awaiting a tyre

The VFR is also Spanish (there's half of frickin' Europe in there)

To be fair you would do well to spot the KLR in there


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Old 07-10-2013, 06:26 PM   #35
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Default Re: KLR650 Tengai project in the UK



Did I find it? Do I win the Tengai?
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Old 07-11-2013, 04:49 PM   #36
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Further ripping down today - now well and truly a bucket of bolts

Powder coating will commence in the near future



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Old 07-19-2013, 02:46 PM   #37
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The tengai is now stripped and almost ready for powder coat.

I am prepping the YTM200 for trike fest, so have got lots to do. A weekend of camping with some of my boys (I have 4 in total) We will also be taking a tri zinger and a minimoto quad.

New drive end bush on the camshaft and cam chain adjust.



Tappet clearances adjusted.



Ready for TF now



This was our last outing:




Last edited by Ten-guy; 07-19-2013 at 02:51 PM.
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Old 07-19-2013, 05:56 PM   #38
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Have a great time at trike fest chris, good to see your getting the boys involved.
must get my kids out on their toys in the holidays. my lads got a pw50 chinese copy he got for his 4tg birthday and my girls got a quad (also chinese) who says the chinese stuff is rubbish?? my girls had her quad 5yrs and it's still going strong archie's 6 and his bikes still great (though he needs a bigger one now). Good to give them the bug while they're young..
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Old 07-20-2013, 10:57 AM   #39
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Will somone please identify for me the square black module mounted inside the mag cover in TENGuy's pic?

Thank you,

Jim
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Old 07-20-2013, 12:34 PM   #40
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Quote:
Originally Posted by Jim Sizemore View Post
Will somone please identify for me the square black module mounted inside the mag cover in TENGuy's pic?

Thank you,

Jim
Hi Jim,

I think you are referring to the CDI pickup coil. This picks up from a metal piece on the flywheel and triggers the CDI to send a voltage pulse to the ignition coil to produce a spark at the appropriate time.

Chris.
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