KLR250 thread

[redneckdan]

I just got done rebuilding the forks on my wifes 250. For future record the damper rods use a 9/16" nut as a holder tool, the klr650 uses a 5/8" nut. I was bale to find the 650 info on the internet but not for the 250. I had to jamb a piece of 1x1 down the damper and use the air impact to spin the bolt out.

klr650 damper rod holer 5/8" nut

klr250 damper rod holder 9/16" nut

[dfye55]

I need bash plate for the Utah backcountry discovery route http://www.backcountrydiscoveryroutes.com/UTBDR this summer. I see the Ricochet and a TCI,. The TCI includes side guards. Are side guards overkill? I'm an older conservative rider, but I have dropped the bike several times riding enduro routes.

Richochet http://utahsportcycle.com/store/klr250pic.htm
tci http://www.motorcyclegear.com/parts/...r250_1987.html

Thoughts, other recommendations?

[newcastleadam]

Originally Posted by redneckdan

klr650 damper rod holer 5/8" nut

klr250 damper rod holder 9/16" nut

For the KLR250 damper rod you can also use the back of a 13/16" spark plug socket (also the Super Sherpa).

[XDragRacer]

Originally Posted by dfye55

I need bash plate for the Utah backcountry discovery route http://www.backcountrydiscoveryroutes.com/UTBDR this summer. I see the Ricochet and a TCI,. The TCI includes side guards. Are side guards overkill? I'm an older conservative rider, but I have dropped the bike several times riding enduro routes.

Richochet http://utahsportcycle.com/store/klr250pic.htm
tci http://www.motorcyclegear.com/parts/...r250_1987.html

Thoughts, other recommendations?

The "ears" of the Utah Sport Cycle/Richochet (I think they're the same) bash plate do a good job of protecting the water pump housing and plumbing, in my experience:





Hogged out the oil drain hole for better flow path, avoiding bash plate when draining oil.

[dfye55]

Love the rocks eye view, thx

Sent from mobile

[XDragRacer]

Originally Posted by dfye55

Love the rocks eye view, thx

You're most welcome!

TCI makes good products; I think I may have one of their stone guards:



I notice the Utah Sport Cycle/Richochet guard sells for $ 84.95; the TCI number for $ 224.95 (on sale); your bike, your call! IMHO, either product would be o.k; your preference and pocketbook remain key in your decision.

[8gv]

I installed a Ricochet brand bash plate on mine (after I stoved in the case). It works better than expected because so far I have zero crashes on it. I have dragged it over several logs and rocks though.

I did takes steps to mitigate the ringing noise that reflects off the plate back up at me. I cut some auto heater hose and wrapped it around the frame where the bash plate might touch it

[skypilot]

I have had a Ricochet plate on my 08 KLR650 since it was a few months old. I have landed on it hard enough to destroy the engine several times. Works great still although it could use a hammer and a flat bit of pavement to flatten it out. Best money I ever spent

Originally Posted by 8gv

I installed a Ricochet brand bash plate on mine (after I stoved in the case). It works better than expected because so far I have zero crashes on it. I have dragged it over several logs and rocks though.

I did takes steps to mitigate the ringing noise that reflects off the plate back up at me. I cut some auto heater hose and wrapped it around the frame where the bash plate might touch it

[Grinnin]

Originally Posted by DrMoto

Got a couple of 1.5W lights from superbrightleds.com (PLM series) . . . . They look a bit yellow from off-axis; more white head-on.

I am copying you shamelessly. I bought these for my KLR because I saw your post.

First surprise: superbrightleds.com charges only $2.99 shipping on $11.90 of product. This is great in an era of deceptively low prices and huge shipping charges.

Second surprise: The housings are aluminum. I don't know what waterproofness standard IP65 is, but I'll take a dip.

The light is bright and wide. The cone of white light is about 90-degrees (45-degrees each side of cenerline) then there's a narrow but distinct yellow halo around the edge. Your photo above is of this halo.

I'm even going to copy your mounting location although I'm handicapped by having only the 650 KLR. (I found your post by kinda thinking that a 250 would be nice.)

[newcastleadam]

Still putting together my as yet non-running 250 and a friend noticed two tapped holes on the swingarm. He convinced me I should put a mudguard there, and we fabbed one up.



Although it is Euro-spec (Belgian), seems to fit well

[8gv]

Nice mud guard. What's left to make the bike run?

I'll likely be flying over Gainesville this week on my way to St Pete. If you see a minimalist (2 seat) plane fly over, it's me.

[newcastleadam]

Originally Posted by 8gv

I'll likely be flying over Gainesville this week on my way to St Pete. If you see a minimalist (2 seat) plane fly over, it's me.

Dude, most of the planes out of and into Gville have rubber bands

Originally Posted by 8gv

Nice mud guard. What's left to make the bike run?

Turning into a medium-term project, hoping the end is in sight. Newest issue is the low compression. Needs a ring job, dug into it more and the piston is a 1 over (0.5mm) plus an icky cylinder and valves. Going to take the piston and cylinder to a machine shop and get them spec'd, then either go with new rings or a 1.0mm over piston.

It's fun getting a project bike that's been through 3 hands of "experts"; missing pieces, bits that are in the wrong places, and stuff that's plain wrong. Then there's the natural decay of a bike that remembers when the Mets won the series

[XDragRacer]

Originally Posted by newcastleadam

Going to take the piston and cylinder to a machine shop and get them spec'd, then either go with new rings or a 1.0mm over piston.

Your proposed course is probably better, but . . . ain't there a 300 cc option with another Kawasaki model piston and pin?

An aftermarket specialist speed shop specializes in Mojaves and KLR250s (http://www.cycleworksracing.net/mojave.htm); sells several kit options from .020 and .040 oversize pistons to combos from 280 cc to 345 cc,.

No personal experience with the firm or its products, but intrigued!

[newcastleadam]

Was also intrigued with Cycleworks with my first KLR250 project, the scope on this one keeps increased with each system as problems surfaced. At this point want to get it running and enjoy it, then look at making it go faster. I believe you can resleeve it with KSF300 Bayou stuff, but cost comes into it at some point. At some point

Started out as a $150 project, starting to get closer to $750. That's the bad. Good news is I'm running out of problems to diagnose and systems to go through. Of course, it ain't running yet so...

[Voidrider]

A couple years ago I picked up a very "basket case" KLR 250 for $200. The big selling factor for me was that it actually had a good title, and I figured I could work on it piecemeal as money came in to allow progress. It is missing a LOT...including the upper engine and carbs, most of the plastic, gauges..but I I figured this would be great to customize. Hell, maybe even put a Ninja 250 into it and make a "Mini - Super Rio" or American made KLE 250...

But then life happened and other projects demanded attention.

I am hoping to get going on it this year, probably first get the manuals and tear down and go through what I have on hand, and research options as I rebuild it. I will be going through this thread for tips and hints for sure!