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Project Rusted KLR600

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Murdo, Jun 21, 2020.

  1. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    My mate Sean bought himself a $200 1985 Kawasaki KLR600. He knew that it had been sitting outside for the last 6 years under a cover and that the engine was 'stuck' (famous last words). He brought it over for me to 'unstuck' it thinking that some Diesel down the plug hole left for a few days would get it free and I would be able to get it running. When I pulled the plug it was rusty on the end (a sure sign of water in the cylinder) and the carb had had water in it from the engine end too? The exhaust was very rusty with holes in the lower sides of the bends. I managed to get the head off and found this.
    Rhylstone RTE 009.jpg Rhylstone RTE 011.jpg
    By using a long lever on a socket on the crank nut and belting the top of the piston with soft faced hammer I got the piston the move and with more belting and levering got the barrel off.
    Carb.
    Rhylstone RTE 013.jpg
    Bit of Diesel was never going to fix that.
    Got the piston off and found the small end of the rod has been mangled by some butcher and badly galled from lack of lubricant. Piston also has galling marks in pin holes.
    Rhylstone RTE 019.jpg
    At this point a full strip down became necessary, and just as well I did as there was sand in the clutch cover. The oil strainer had plenty of alloy and old gasket bits in it too.
    Rhylstone RTE 017.jpg
    Imagine the damage if I had started it and this had gone through the engine.
    Rhylstone RTE 015.jpg
    On quizing Sean I found out that the PO has a couple of small boys and I am guessing they may have 'helped daddy's bike' by putting the hose up the exhaust and hiding sand in the engine. Anyway, we are now looking for a piston, conrod and gasket set. Seems conrod kits are pretty rare so we may have to take to engineering shop and get the small end bored and bronze bush fitted back to standard size. Will replace the output shaft seal and bearing which is a bit rough but all other bearings are good.
    His $200 bargain may turn into a $1200 bike yet.
     
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  2. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    Got the cases welded and washed up. Went and bought the bearings and seals and home to open (don't need the bearing seals in gearbox) and have a look at where this SKF bearing was made and how much grease in it.
    xxx 002.jpg
    Then look at this one made in Malaysia.
    xxx 004.jpg
    Bit of a difference.
    Went to favourite machinist and he can rebush the rod still on the crank for $200. Now looking for a replacement rod kit that I hope will be cheaper, but can still go back to him if unable to find one.
    Gears assembled into right case waiting now for crank.
    xxx 006.jpg
     
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  3. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    Head and barrel blasted, valves and seats cut (not my best job but considering what I had to start with it is ok), valves lapped and now waiting for parts again.
    xxx 003.jpg xxx 005.jpg
     
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    Last edited: Jun 24, 2020
  4. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    Got the gasket kit and now valves are in head, but of course with the grinding/seat cutting all the shims are out so off to see Mr Kawasaki shop tomorrow.
    Have been working on the frame while waiting for engine bits. The shock linkage was seized and the main bolt holding the linkage in was also frozen in the frame. I made up blocks and put in the press and with 12 ton and a lot of heat finally got it out. New bearings in links with lots of fresh grease and all back together. Forks got new seals and oil, steering head bearings (tapered rollers) fitted, frame sandblasted and two pack black and new front tyre fitted. Shock regassed and spring repainted, all switches and wiring checked and tested, cables lubed, broken instruments repaired and lubricated. Still waiting to get rod end repaired before I can re assemble the engine.
    Hayley visit July 2020 024.jpg
     
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  5. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    Engine is now all together, in and running.
    Checked the crank and at 0.004" runout was withing the spec limits so left alone.
    More Tiny House 013.jpg
    New piston looks SO much better than the rusted piece I had to hammer out.
    More Tiny House 015.jpg
    Engine in and running.
    More Tiny House 021.jpg
    Waiting for paint to arrive before doing all the plastics.
     
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  6. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    That is such a magnificent restoration, most would have taken one look ad thought boat anchor, I know I would have
     
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  7. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Thanks. That is probably why people bring the really shitty ones to me.
     
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  8. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Well that was the mechanical equivalent of a resurrection
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    Painting done.
    Wendy's crash 005.jpg
    Spent the afternoon making the rusted rear blinkers work. Had to end up sandblasting the bulb holders and resoldering the wires to make good contacts.
    Wendy's crash 003.jpg
    Should get the seat back tomorrow and be ready for testing.
     
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  10. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Ah, the gift that just keeps on giving (me trouble)
    Fitted the tank and hoses on, added fuel and started engine only to see small puffs of vapour rising from the exhaust pipe where petrol from a tiny pin hole in the tank was dripping onto it. Quickly stopped the engine before all my good work turned to ashes. Tank off and drained, clean up hole and leave in sun for fuel to evaporate. A dob of brazing to the hole and all petrol tight. Some paint (to hide the brass), back on bike and fuel in. :thumb_ups:
    triumph frame repair 007.jpg
     
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  11. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    And still giving! The seal on the gear shaft has now decided to start piddling oil. Got new seal, gear lever off, drilled two plaster screws into the seal.
    xxx 004.jpg
    xxx 006.jpg
    Then using a pair of pliers and multi grips pulled the seal out.
    xxx 009.jpg
    Tapped new seal in with sparkplug socket and all is good. Lever back on ready to ride.
     
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  12. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    1938 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, VT250F2, FT500 plus a few others.
    It's finally gone, three months it has been here on my worktable.
    xxx 001.jpg xxx 002.jpg
    Couple of things are not 100% but it is going to be used on dirt roads/tracks so no point making it too pretty. He got it registered today.
    When Sean picked it up I said to him "NO more of your rusty crap bikes". Think he got the message. :lolsign:
     
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  13. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Sean has finished the last few bits of the KLR and it looks sweet. He had to re-tension the cylinder head to stop a small coolant leak when the engine got hot, but has had no other troubles.
    xx 002.jpg
     
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