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Old 04-04-2013, 09:43 AM   #1
Eaglemike
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Default engine balance

Once in a while people ask why the forged pistons make the engine smoother. Well, it's interesting. The aftermarket pistons we sell are lighter than the stock stuff. The next question "Should that make the engine rougher? After all, Kawasaki knows what they are doing, and they balanced the engine." The engine counterbalance system was designed for the KL600. The 600 had a shorter stroke, and smaller bore, which also means lighter piston. Depending on design, one could make it as heavy as the 650 piston, but I'm willing to bet that the 600 piston is lighter than the 650. Remember the 600 wasn't really a 600, it was a 565. Bore and stroke 96 X 78. The big end also had a smaller bearing size. IIRC the wrist pin was smaller diameter. This all affects reciprocating weight.

I've compared part numbers for the balancer parts. The 600 used the same balancer weights as the early 650. I've weighed the muli-part sprockets and the post 1995 one-piece sprockets, and they are the same within manufacturing tolerances.

Bottom line - the engine balancing system was designed for the 600, and not re-balanced for the 650.

We have yet to find a piston light enough that the vibes got worse......
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Last edited by Eaglemike; 04-04-2013 at 01:25 PM.
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Old 04-07-2013, 09:14 AM   #2
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Default Re: engine balance

Thanks. Interesting stuff.
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Old 04-07-2013, 09:15 AM   #3
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Default Re: engine balance

Quote:
Originally Posted by JBradley500 View Post
Thanks. Interesting stuff.
Agreed!
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Old 09-12-2017, 08:07 AM   #4
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Default Re: engine balance

Hi, whilst looking at the left hand counter balance weight on a 1990 Tengai motor I noticed that it can be rotated a few millimetres back and forth independent of the sprocket. sprocket and chain stay still, can anyone tell me if that is acceptable, thanks.
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Old 09-12-2017, 03:28 PM   #5
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Default Re: engine balance

Quote:
Originally Posted by BareBones View Post
Hi, whilst looking at the left hand counter balance weight on a 1990 Tengai motor I noticed that it can be rotated a few millimetres back and forth independent of the sprocket. sprocket and chain stay still, can anyone tell me if that is acceptable, thanks.
You need to replace that sprocket. The engines prior to mid 1996 had multi-piece sprockets, prone to failure. Seen more than one that grenaded the engine. One of the guys had a huge thread on here years ago - and he lived in Oz too.

The later stuff installs easily, plug-n-play.
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Old 09-12-2017, 11:31 PM   #6
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Default Re: engine balance

Part numbers needed to upgrade...

Kawi Parts:
12046-1165 Sprocket upper/rear
92022-1880 Thrush washer - goes inside of the upper rear sprocket
13164-1007 Front lower sprocket/weight assembly
2ea 48052000 C clips
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Old 09-13-2017, 01:38 AM   #7
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Default Re: engine balance

Thanks, I'm guessing it's some sort shock absorbing spring system built into the sprocket that they just decided to do away with in '96. and it's only the one with the counter weight on it, the other two are solid and can be left in place. The doo was the original and there is a couple of centimetres of the bottom rail broken off and still unaccounted for, I received my E.M. doohickey and coil spring kit #22519 today.

I my daily ride is an '04 A a lucky buy, the previous owner spent $ on it, then had to change his plans, got the bob the doo full Vance, jetted, every eagle mike add on available ect, runs great. I've since bought a cheap Tengai motor to practice on and have ready for when my motor finally needs refurbishing, Swap them over and keep riding whilst applying what I've learned to the other engine

If anyone is still reading I just want to say how much I love my KLR, my first bike brand new when I was 16 was a Z200 I had it 3yrs, my only transport, even took it to the UK with me and rode through two winters to and from work, all around Scotland, I loved that thing, since then I've owed 30 plus bikes from Shovels to a 900ss and FJR everything in between, now 40yrs later I've put 25k kms on my KLR over 20 mths and feel the joy I experienced on my first bike, that I never quite got from the others as I nip around and purr along with a little smile, on a simple solid Kwaka single, I feel I've come full circle.
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Old 09-13-2017, 01:48 AM   #8
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Default Re: engine balance

Thanks for that Chuck, I didn't see the info until after I'd posted, it's all three sprockets, plus clips and a thrust washer, and I'm guessing the advice would be, 'really should replace the chain,' eeek I hope this project doesn't turn into a money pit!
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Old 09-13-2017, 10:42 PM   #9
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Default Re: engine balance

Quote:
Originally Posted by BareBones View Post
Thanks for that Chuck, I didn't see the info until after I'd posted, it's all three sprockets, plus clips and a thrust washer, and I'm guessing the advice would be, 'really should replace the chain,' eeek I hope this project doesn't turn into a money pit!
I have never seen a worn out balancer chain...even with high mileage and worn out sprockets. Service manual walks you thru how to check but again...I've never seen it.
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Old 09-13-2017, 11:41 PM   #10
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Default Re: engine balance

Cheers, that's good to hear. I've bought all three sprockets and guides from the USA off a 2016 low mileage bike being wrecked on ebay (mattmattmotorcycle) doing those and the doohickey reduces the likelihood of catastrophic failure, the rest should be a freshen up. I had my ear against it whilst it was running, before purchase, sounded smooth, the normal whirs and whooshing.
I really appreciate you sharing your experience, thanks
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Old 09-14-2017, 09:18 AM   #11
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Default Re: engine balance

I've seen a few, but vary rare. Most of the wear is due to the rubber on the sprockets getting chewed by the chain. It wears a lot more when there is excess slack.
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Old 09-14-2017, 06:18 PM   #12
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Default Re: engine balance

Another reason to install an Eagle Mike doohickey and torsion spring, as it will more than pay for itself over time and provide that priceless, peace of mind.
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