KLX replacement cylinder head compatibility.
 

I cleaned up all parts after removing cylinder head and cylinder. Found a couple of problems with my replacement cylinder head.

I bought a head from a 2009 (Carb bike from the states which i sent to Bill Blue to have ported and bigger valves fitted. I have now come to fit my BB kit and head. Alas the head is slightly different. The Rubber mount for the EFI throttle body on my 2010 does not fit the 2009 carb head. The centres of the bolts on my head are 75mm where as the carb head is 63mm. Any suggestions how to get past this problem???

https://www.kawasakiforums.com/forum...75-mm-4148.jpg

https://www.kawasakiforums.com/forum...63-mm-4147.jpg


https://www.kawasakiforums.com/forum...-hole-4144.jpg



My 2010 EFI (Asia model ) Also has a Temp sensor on the head. On the ported head there is a blanking plug. But the thread size is different. I could drill and tap it out to the right thread. But the Temp probe would sit 10 mm more into the water jacket. I am concerned that it may impede water flow and cause a hot spot. Anyone have any experience with this ?


https://www.kawasakiforums.com/forum...-hole-4146.jpg

I will wait to see if any of you guys have any feed back before i start modifying the carb head.

Fitted piston rings while waiting.

Cheers

1. Install a larger piece of pipe, threaded to head on one end, inside threaded to sensor on the other end. Better yet see answer 2.
2. Are the ports larger on the FI? Two options, have a machine shop insert new head bolts & cut the other ones off ... or get a slide carb and get rid of the FI.

Others may have more reasonable responses.

Yes, I was thinking of trying to get a piece of stock brass and borrowing a lathe. I live in Indonesia. Machine shops are not easy to find here.

Cheers.

George

In the end i managed to drill and tap the hole out so i could screw the temperature sensor in. Needed a copper washer to space out a wee bit.
The Throttle body rubber mount was fitted by elongating the holes.
Job done. Just hope there are no leaks .
https://www.kawasakiforums.com/forum...-1154-4161.jpg

Looking good.