Rebuilding 2008 KLR Part 3

It’s been quite a while since I last posted. But I have been making some progress on the KLR. I’ve mostly been focusing on dissasembling the new engine in order to do the 685 kit on it. I’m using the Schnitz Racing kit.

I bought this engine stand off of Revzilla in hopes that it would be able to hold the new KLR engine on my workbench and it actually works perfectly:

The instructions that came with the kit were really thorough and taking the engine apart to get the cylinder out was pretty straightforward. Here you can see the top of the engine removed and the camshafts:

Once the cam shafts were removed I could get access to the piston, which as you can see had quite a lot of carbon scoring on it:

This is more or less how the engine looks right now with the cylinder and the piston removed:

The cylinder is off at a machine shop where it will be re-bored to hold the new, bigger piston that came with the kit.

The top of the engine looked really crummy:

I attempted to sand it down and scuff it up to adhere to new paint. I used some Rustoleum engine paint that came in a rattle can and you can see the final product below:

I really had no idea what I was doing but it looks OK in the end. No one will notice it and it at least looks better than before. Although it’s a lot more glossy than the rest of the engine is so it might look like a little weird once it’s re-assembled.

Next up is getting all the old gaskets and gunk removed and hopefully getting the cylinder back from the machine shop so I can start putting everything back together again!