KLR 685cc Kit
KLR 705cc Kit
Instructions
For 1996-2010 KLR650A
• Note – This kit is to be installed in a 1996 or late block. With that done, it will fit all years of KLR650 from 1987 to present.
• Choose compression ratio
o There are 2 included base gaskets. One is .010” thick, and the other is .020”. They can be stacked together for .030”.
o The piston is designed to be 9.8 to 1 (9.9 on ’08 models) with the .020” base gasket. That is the recommended compression, for use on 89 octane fuel. Using the .010” gasket alone will increase compression to 9.98 to 1 (10.08 on ’08 models). This is recommended only if using a longer duration intake cam, or if premium fuel is used exclusively. Stacking both gaskets together will lower compression to 9.62 to 1 (9.72 on ’08 models). This should be used if fuel quality issues are expected.
o Note: That for ’08 and later models using a modified head, the compression ratios are dependant on chamber volume. Pre-stage through stage-2 head chamber volumes are set to match the 07 & earlier heads. So, the ’07 compression numbers of 9.62/9.8/9.98 apply. The higher numbers only apply to stock, unmodified ’08 heads.
• Assembly
o Wash the cylinder in warm soapy water and dry. Wipe the bore clean with WD-40 and a clean rag. Install the piston on the connecting rod. Use a drop of oil on the pin. Install the base gasket. It is easier to lay a couple of dowels under the piston skirt. These will hold the piston square with the base. Set the cylinder on top and screw two of the long head bolts in to help hold the cylinder. Verify the ring end gap positions one last time. Smear 1 drop of oil on the piston skirt. Use no oil on the rings, or on the bore. Carefully work the cylinder down over the rings. Rotate the engine over a few times by hand. There should be a smooth light drag. Assemble as per the factory, or Clymer service manual. Use stock torques. NOTE – Use no gasket sealer on the head gaskets. (See image on next page.) All gasket surfaces need to be very clean and dry.
• Break in
o Before the first fire up, change the oil & filter. Use a cheap 10w30 or 10w40 mineral based oil. No synthetic. Warm the bike up fully. Ride the bike somewhat easy for 5 to 20 miles. DO as much engine braking as possible. NO steady throttle cruising! Change the oil and filter again using a premium grade, non-synthetic 10w40 or 15w40. Over the next 150-200 miles work the engine progressively harder. Best if done in 2-3 or more sessions with a cool down in between. Again, use as much engine braking as possible. Go through the gears as much as possible. There are no RPM limits, just “work” the engine a littler harder each time, then back off. Change the oil and filter again after this period. You can now use a synthetic oil (recommended). Use a 15w50 or 20w50. Avoid any extended high RPM runs for another 100 miles.
o The head bolts do no need to be retorqued, but it does not hurt to do so. You should recheck the exhaust bolts and other hardware about this time.
• Re-Jetting
o The piston kit alone will not require any jetting changes. If it was correct before, it should not change much, if at all.
o Note – Because this piston is forged, it should be warmed up a little longer before riding. You may also hear a bit more noise when cold. The PCV valve mod is also recommended with this piston kit.
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KLR-705 Piston Specifications
1996-2010
Schnitz Racing
222 N 3rd Street
Decatur, IN 46733
(260)728-9457
Motor Type: Kawasaki KL650-A Actual Displacement = 703.60cc
Displacement:
Piston Type: Flat Top
Bore: 4.090” (103.89mm)
Stroke: 3.268” (83mm)
Flat Top
Comp. Dist: 1.208 (30.68mm)
Int .156 (3.96mm) 27 Deg
Exh .141 (3.58mm) 28 Deg
Valve pocket dept measured from Deck
Groove Land
Top .48 (1.22)mm) .210 (533mm)
2nd .060 (1.52mm) .140 (3.56mm)
Oil .119 (3.02mm) .110 (2.79mm)
Pin Dia .945 (24.00mm)
Pin Length 2.250 (57.15mm)
JE .073 Wire Locks
Actual Weight 399 Grams
Total Assembled Weight
With Rings–Pin 554 Grams
Stock Assy 641 Grams
Valve Reliefs will clear 40/36mm Valves
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IMPORTANT CLEARANCE INFORMATION GUIDELINES ONLY
Set clearance to .0024” (.06mm)
Some applications may require more clearance. Measure piston diameter .275” (7mm) from bottom of piston skirt
Minimum clearances (coated) .0022”
CORRECT PISTON INSTALLATION IS THE RESPOINSIBILITY OF THE CUSTOMER
Minimum ring end gap is .019”
Ring Markings face up (dot or letters)
Oil Rings are not marked
Note—Compression height is .010” lower than stock piston at outer edge. Stock piston is dished slightly
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