SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Cylinder Removal
Remove the cylinder head. See the Cylinder Head topic for more information.
Remove the exhaust pipe. See the Exhaust Removal topic for more information.
Remove the starter motor. See the Starter Motor Removal topic for more information.
Remove the bolt securing the oil pipe to the cylinder using an 8 mm wrench.
Note the location of the dowel pins in the cylinder.
Remove the cam chain guide holder.
Remove the cam chain guide.
Remove the front and rear cylinder nuts using a 12 mm wrench.
Lift the cylinder free from the studs. You may need to tap the cylinder gently with a rubber mallet to break it free. Be careful not to damage the cylinder. Protect the piston and connecting rod from damage as the cylinder is removed – the piston or rod could be damaged if they are allowed to fall against the engine cases.
Cylinder Inspection
Cylinder
Measure the cylinder bore using a dial bore gauge. Measure the cylinder bore 10 mm from the top, at the middle and 20 mm from the bottom of the cylinder from front to rear and from side to side, for a total of six measurements. Compare your measurements with specification.
Cylinder Diameter
KLR650
Standard: 100.00 – 100.012 mm (3.9370 – 3.9375)
Service Limit: 100.10 mm (3.941 in)
KLR600
Standard: 96.000-96.012 mm
Service Limit: 96.10 mm
KLR500
Standard: 89.000 – 89.012 mm
Service Limit: 89.10 mm
Rings
The rings should be replaced with new ones any time the cylinder is removed, there is no need to measure the old ones for wear.
Cylinder Installation
Clean all gasket surfaces using an aerosol brake cleaner and a gasket scraper. Install a new base gasket on the engine cases. Lubricate the cylinder and piston skirt with engine oil prior to assembly. Pass the timing chain, properly secured with a wire, through the cylinder so it is not in the way and remains accessible when it comes time to re-install the cylinder head.
Insure that all dowel pins are in place and fit the cylinder onto the cylinder studs. Carefully work the piston into the bore making sure the piston rings do not snag at any point. A ring compressor will make this job easier.
Tighten the front and rear cylinder nuts using a 12 mm wrench.
Cylinder nut torque: 25 N-m or 18 ft-lb
Reinstall the cam chain guide.
Install the dowel pins in the cylinder if they were removed.
Install the bolt securing the oil pipe to the cylinder using an 8 mm wrench.
Install the starter motor. See the Starter Motor Installation topic for more information.
Install the exhaust pipe. See the Exhaust Removal topic for more information.
Install the cylinder head. See the Cylinder Head topic for more information.