As I said, I'm the 3rd owner at 1,800miles. The KLX has now 5,100 miles and has its problems starting around 2,500 miles. I've just went along with it for now, but its something that is going to need to be fixed. On a side note, the previous owner did mention at the time I bought it in April 2007. He was running 100 octane. Kinda of a indication that he might have been racing it hard. I will usually run up to 5-6k rpms between shifts and the rpms around 3-4k for low-speed cruising. This is a good chance for me to open the engine and check parts.

Before anyone asks this, its not valve clearance. Trust me, I've checked the valves three time since I owned it. And its always remains dead center on. Along with Cam timing before.

 

Got my parts today. Unfortunely, I forgot to order a head gasket as well. So this weekend, I'll be working on the KLX cam chain. Lots of photos to come afterwards.


Cam Chain, Part # 92057-1416, $79.88


Flywheel holder tool, Part # 57001-1313, $234.17 (I got it at $205)


Valve spring compressor tool w/ spring adapter, Tool Part # 57001-241 / Adapter Part # 57001-1202 ,Tool $98.39 / Adapter $23.15. The Valve spring compressor comes with a spring adapter but its the wrong one and is meant for larger springs. So you need to order the correct adapter with it.

 

Man $205 for a flywheel holder wow.

 

I wish you lived closer you could borrowed, hell I would have helped you before you spent that much.

 

No kidding. I think me heart stopped for a second when I found that out. It will be still usefully to keep. I have 3 motorcycles, well I own 1 of them (06' KLX250s, 85' Honda NightHawk 650cc, 07' Yamaha Virago 250cc).

 

The problem has been solved. It took 7 hours of work, but after all said and done. I love how it sounds now. No more wrench banging monkey inside the engine. Nice and smooth at idle. Pulls all the way through without a clank. The KLX is actually an easy engine to work on. Just gotta have the correct tools and the repair manual to help along.

A few good tips and tools:
New gaskets: They rip easy and may leak after you reinstall everything
Hi-Temp RTV Silcone: If a leak if found, use this to fix it. My water pump leaked afterwards, this fixed it.
Torque wrenches: Highly recommended, will make sure that aluminum doesn't strip out.
Lubicant Spray: Any kind works, use it for every bolt that goes back in. Most of the bolts that I pulled started corroding.

And yes, lots of pictures.

Photo of the KLX before I begin work


Plastics and seat removed.


Draining fuel



Fuel tank removed



Clutch cover removed



Left engine cover removed. Fly wheel holder tool in use.


Right engine side cover removed.


Bottom of Cam Chain


Clutch plate removed




Engine top-end and cam shafts


Cam chain removed after removing cams and water pump drive.


Cam chain lenghts between old (top) and new (bottom)



Clutch pressure plates.


Final results of all the hard work.

I'm glad the clanking is stopped. KLX runs great now and the valve clearance is still dead within spec. Hope this helps some. If needed, I can scan the pages of the repair manual for that need it.

 

That's great man!! Glad you got it fixed. Was the problem that the chain had stretched, or the guides were worn, or both? I just had to replace the tensioner on my klr. It got rid of the clatter but I still have a jingle sound at 7k. We need to get together and ride sometime.

 

Should of big bored and cammed that puppy after all that. lol! Nice job Post your findings on the chain stretch if you don't mind.


Kevin

 

Bore up and cams would have been easier, with or without doing a cam chain. But it did cross my mind. Best time for the bore up is when I have to go back into the top-end for valve seals replacement. As for chain stretch, good idea. Since you mentioned it, I quickly recovered the old parts from the soon to be trash. I'll try to measure it tomorrow, but will be unable to measure the new one cam chain for comparision (its already installed).

Next project: Fix the riding lawn mower clutch and replace belts. Oh the joy of never ending fixes.

 

Never ends does it!