07 650i 5000 mi advice on where to send valve bodies - Kawasaki Brute Forum
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post #1 of 12 Old November 24th, 2018, 06:57 AM Thread Starter
 
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07 650i 5000 mi advice on where to send valve bodies

My 650 was blowing by the rings so bad that it was spaying oil mist out the dipstick and routinely spraying into the airbox. The compression (cold... i know) was approx. 40 psi on both. Pressure tests (at 65 psi) in each cylinder at TDC showed no audible leaks on the front int and exh, only hissing out thru the dipstick. The rear cylinder at TDC had air hissing out the carb and dipstick.

I've got the top end apart (don't have enough money right now to throw at a true rebuild) but will lightly hone and new stock rings. I would like to send the valve bodies to a shop to have them inspected, new guides, seals etc.

Any help appreciated!
Bob

2007 BF 650i; Bigger jets, EPI springs, HMF muffler, K&N Air, CDI, engine brake override, reverse 4WD override, EPS just added. 26's just added.
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post #2 of 12 Old November 24th, 2018, 06:59 AM Thread Starter
 
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also, was wondering if these heads can be decked by say 10 or 20 thousands without interference trouble?

2007 BF 650i; Bigger jets, EPI springs, HMF muffler, K&N Air, CDI, engine brake override, reverse 4WD override, EPS just added. 26's just added.
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post #3 of 12 Old November 24th, 2018, 11:46 AM
 
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The one clearly needs a valve job but might as well do both. Your dealer's shop should be able to do them. Check your ring gaps is several positions on the cylinders. You might find they need boring to correct the blow-by. And not 20 thousands but 10 and less on decking is possible. There's only about 18 thousands clearance between piston and valves during overlap as I recall.

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post #4 of 12 Old November 24th, 2018, 06:39 PM Thread Starter
 
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thanks for advice. i have a question on the ring gap. i'll take the new rings and check them in the bore for end gap. Are you saying i may need to bore the cylinders because the end gap will be too big, which is causing blow bye?
If I bore them they'll need to be treated/coating - correct?

2007 BF 650i; Bigger jets, EPI springs, HMF muffler, K&N Air, CDI, engine brake override, reverse 4WD override, EPS just added. 26's just added.
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post #5 of 12 Old November 24th, 2018, 10:11 PM
 
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You can tell how warn the cylinder is by checking the end gap in several places. If it is outside the usable range then it will need boring, re-plating, and the correct rings and pistons.

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post #6 of 12 Old November 26th, 2018, 11:18 AM Thread Starter
 
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Quote:
Originally Posted by NMKAWIERIDER View Post
You can tell how warn the cylinder is by checking the end gap in several places. If it is outside the usable range then it will need boring, re-plating, and the correct rings and pistons.
OK, that's what I thought.
I had our machine shop at work use a bore gauge and measure as per the book.
Front cylinder was very uniform at 3.153" which the book says is the service limit.
Rear cylinder was also uniform at 3.1515.


So now my question is, what is the most cost effective fix? Do I find a place that can bore and re-plate? or get another set of cylinders?


Thanks again for advice.

2007 BF 650i; Bigger jets, EPI springs, HMF muffler, K&N Air, CDI, engine brake override, reverse 4WD override, EPS just added. 26's just added.
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post #7 of 12 Old November 26th, 2018, 02:28 PM Thread Starter
 
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bigger rings vs. bore?

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Originally Posted by rlangell View Post
OK, that's what I thought.
I had our machine shop at work use a bore gauge and measure as per the book.
Front cylinder was very uniform at 3.153" which the book says is the service limit.
Rear cylinder was also uniform at 3.1515.


So now my question is, what is the most cost effective fix? Do I find a place that can bore and re-plate? or get another set of cylinders?


Thanks again for advice.
I'm looking at options to get my quad's compression back. Since i'm right at the service limit of bore size, but my cylinders look good honed, does it make sense to measure the piston ring grooves diameters, with the bores, and determine a piston ring size. Say 15 thou over?

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post #8 of 12 Old November 26th, 2018, 06:25 PM
 
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Quote:
Originally Posted by rlangell View Post
I'm looking at options to get my quad's compression back. Since i'm right at the service limit of bore size, but my cylinders look good honed, does it make sense to measure the piston ring grooves diameters, with the bores, and determine a piston ring size. Say 15 thou over?
Screw it- if they are that good just drop a set of stock rings in it. Be careful with the honing though...go easy. That plated material isn't very thick and its lost some already.

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post #9 of 12 Old November 27th, 2018, 09:36 AM Thread Starter
 
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Screw it- if they are that good just drop a set of stock rings in it. Be careful with the honing though...go easy. That plated material isn't very thick and its lost some already.
Yeah that's what I'm thinking too. My bore/hone measured up pretty good-very little variation. I tried to go easy on the hone. I'm going to use stock pistons again but I've ordered 0.010 oversize rings. My plan is to grind the correct end gap for each of the four rings plus make sure the oil ring is set. I'll check the compression and report back.
I've dropped the valve bodies of at local quad shop for testing/measuring/re-building as required.

2007 BF 650i; Bigger jets, EPI springs, HMF muffler, K&N Air, CDI, engine brake override, reverse 4WD override, EPS just added. 26's just added.
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post #10 of 12 Old December 5th, 2018, 12:24 PM Thread Starter
 
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update. measured current ring gaps and all were out of spec. I got a set of 0.010 over rings and ground each one to middle of spec. Valve bodies were unfortunately shot, local shop sent them out for machining and rebuild. hopefully have it back together this weekend with new compression values. Decided not to mess with decking the jugs, keep it stock.

2007 BF 650i; Bigger jets, EPI springs, HMF muffler, K&N Air, CDI, engine brake override, reverse 4WD override, EPS just added. 26's just added.
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