I've done the following mods to both my '03 and '05 KLR250s, and have had excellent results:
FMF Q4 Muffler
Drilled four 1/2" holes in the top of my airbox.
I bought OEM jets from jetsrus.com (genuine Keihin)
If your bike runs well and is easy to start, you don't need to "freshen up" the top end. My '03 has 27,000 miles on it and it has never needed top end attention.
Originally Posted by toddzacker
Would like some help with mods for the 2000 KLR250...I saw someone had a cobra exhaust for it, can someone let me know who that was or help find the link to it? Here are the questions I had:
1) recommended exhausts
2) jetting ... Main & pilot also needle settings
3) valve clearances
This should be a good start for the winter mods. I am considering rebuilding the top end if the compression test is a little low. The bike has 8500 miles on it, not sure how long would be recommended before a top end refresh.
Any suggestions & comments will be greatly appreciated.