MegaCity Performance

MegaCity Performance Home of the KLR650 MCP Carburetor Correction Kit

KLR650 Air Cut Off Issues - Almost all cut off diaphragms leak to varying degrees. Replacements start leaking right away...
10/23/2022

KLR650 Air Cut Off Issues - Almost all cut off diaphragms leak to varying degrees. Replacements start leaking right away. Only solution once the cut off starts leaking is to disable or delete it.

To disable it, you change out the o ring with the rubber plug, everything stays where it was. The spring MUST be re installed to hold the cut off valve "OFF".

Deleting the cut off is as simple as using scissors to cut the perimeter off the valve to use as a seal for the cap, then change the o ring for the plug to block the vacuum port completely.

The Plug is included with the MCP Carburetor Correction kit from MegaCity Performance since July 2022. Visit our page or Google us.

People who've done any other kit, then tried MCP.
10/22/2022

People who've done any other kit, then tried MCP.

Parts Ordered for the 2016 block.
10/18/2022

Parts Ordered for the 2016 block.

I'm pricing parts to rebuild the 2016 block i have with a bad small end of the crank. When i do a crank i always like to...
10/13/2022

I'm pricing parts to rebuild the 2016 block i have with a bad small end of the crank.

When i do a crank i always like to replace main bearings as well.

On the left hand page, i did some comparing of the new part numbers to old part numbers for gaskets. You can see in 2 of 3 cases the old number is cheaper than the new number with exception of the clutch cover gasket, the newer number is cheaper and all should work just the same. ODD. Also prices on the left page are the left side gaskets and water pump gasket. The gaskets are common to both 08 & 16 years. (and all years)

Right hand page are crank parts and complete crank shafts. The sprocket for the balancer and cam chains are available but the bearing is not. You can get the bearing and sprocket on an 08 left hand crank half but then you still need a rod kit (bottom of page) and to have a shop press it, the left flywheel for an 08 is 586.58$ Canadian which includes the bearing and sprocket, but you still need a rod kit and to have it pressed. Getting it pressed I'd only trust the machine shop i use in Edmonton. That means at least 1 trip to Edmonton. (Don't want to ship) Gotta count fuel and time, maybe two trips depending if they would make an appointment. This would also mean taking a day off.

A complete crank for a 2008 is 820.61 which includes the sprocket and left hand main roller bearing. same thing for a 2016 is 861.46

Seeing as i'm using 2016 cases, might just order a complete crank and save myself a whole bunch of time and money considering where i live,

The only things not on the list are the front balancer bearings, but i'll probably leave them as they can be changed later if they are an issue.

SO, 1100$ to rebuild the crank on the 2016 bottom end. Plus time.

If the weather holds i could have it done in 3 weeks. LOL

If i cheated and didn't change main bearings i could get away with a rod kit and having the crank pressed, assuming they do it without damaging the roller bearing which isn't available on its own. Seeing as it ate enough sand to ruin rings, valves and the small end of the crank i think it would be unwise not to change the mains even if they sound and look ok.

Think I've made up my mind.

After my whirlwind ride to Bonnyville Alberta i pulled the filter the other day. (pushed the bike hard ish for testing)L...
10/13/2022

After my whirlwind ride to Bonnyville Alberta i pulled the filter the other day. (pushed the bike hard ish for testing)

Lots of metal again,

i think its all goin, transmission, bearings, rod, all slowly wearing because the bearings were damaged when the oil got soo low on the PO. Its impossible to isolate one cause for all the noise from the engine because its all noisy.

i suspect this bike was ridden until it quit, instead of realizing something is wrong an pulling over..

runs and rides fantastic still with the new top end but after i saw the filter I parked it.

if the transmission were to lock up it'd be bad news.

Maybe next year for giggles i'll pull that bottom end apart and see as i'll be repairing the crankshaft on the 2016 bottom end to swap into this bike.

Still runs fantastic, but approaching dangerous now. Got 4800 kms outa that bottom end.

Gonna start pricing parts for this bottom end ;). And in the "Frankenstein" theme, the bottom end will no longer match t...
10/05/2022

Gonna start pricing parts for this bottom end ;). And in the "Frankenstein" theme, the bottom end will no longer match the frame. (Not the block it came with)

2008 Bottom End Oil Flow Chart. (all years) so ... the PREVIOUS head (08) roasted HARD, and was completely destroyed. (R...
10/05/2022

2008 Bottom End Oil Flow Chart. (all years)

so ... the PREVIOUS
head (08) roasted HARD, and was completely destroyed. (Ran low on oil)

If you follow the oil flow chart and consider, the balancer chain tensioner (pressure fed) was bad too, then look at the output shaft. Its the next furthest thing from the oil pump. Both transmission shafts and the clutch bearing are also oil pressure fed.

The Oil pump feeds the crank first, The next to get oil is the HEAD and the transmission INPUT shaft. Lastly are the transmission output shaft and balancer chain tensioner.

In the transmission the freewheeling gears have steel on steel plain bearings and must have oil pressure at all times.

Considering the grit i found on my last cover pop, I know that the transmission is going, the main bearings are complaining and the LEFT Main Bearing is likely going too.

When you consider that the OIL PRESSURE FED balancer adjuster was so far gone, the front shaft (splash fed) bearings were screaming, and the main bearings are groaning, the writing is on the wall.

I took a chance on this bottom end and lost. Which is good actually, for my page and followers. Now we get to do a step by step on a bottom end.

It isn't monetarily feasible to pay someone to do this work on a KLR. Luckily, i don't charge myself.

From what i hear, and what I've seen, its toast. Winter is almost here, its all good. Glad i didn't wait till spring to diagnose, would have left me scrambling.

On the way to Bonnyville AB Great Scenery, Almost NO BUGS and 18-20 celcius (60-65F) Bike ran great as always, engine is...
10/05/2022

On the way to Bonnyville AB

Great Scenery, Almost NO BUGS and 18-20 celcius (60-65F)

Bike ran great as always, engine is still noisy lol.

Instead of hearing the front balancer bearings screaming, i can hear the main bearings moaning and maybe the transmission

160 kms (100mi) with the new balancer bearings. No more screaming bearing at mid-high rpms.all the other noises are st...
10/03/2022

160 kms (100mi) with the new balancer bearings. No more screaming bearing at mid-high rpms.

all the other noises are still there lol. It didn't magically make it a quiet engine, but it is much improved

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Lloydminster, SK
S9V1N5

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