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Old 10-16-2014, 09:55 AM   #1
Chapman87 OP
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The winter project I didnt want - KLR250

Well I traded a car (that I hated) for this little KLR250, it ran and drove pretty good, but the top end sounded terrible. I read that the valves need to be checked a lot on these things so I just ran it to the shop since I didnt have time for a project. Longer story short they called me and said it needs a new cam chain along with the valves needing adjusted. All said and done they want about $800, I cant afford that. So here comes the DIY Winter Project that I never wanted!

What I know it needs...
-Cam Chain
-Valves adjusted
-Various Gaskets/Seals
-Front brake rebuilt/new line

Questions...
Who is a good parts source for these?
Any writeups or videos on replacing the cam chain?
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Old 10-16-2014, 11:08 AM   #2
Bigger Al
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PM sent.
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Old 10-16-2014, 11:19 AM   #3
alansz400
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Swaping out the KLR front master cyl. with a used DR650 master cyl. fixed the front brake problem on mine. I have a new valve cover gasket you can have for the price of shipping if you need it.
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Old 10-16-2014, 12:13 PM   #4
Chapman87 OP
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PM sent.
I havent received it yet.

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Originally Posted by alansz400 View Post
Swaping out the KLR front master cyl. with a used DR650 master cyl. fixed the front brake problem on mine. I have a new valve cover gasket you can have for the price of shipping if you need it.
Thanks, I may take you up on that. It does need a couple more gaskets and seals so I was thinking about buying a complete kit (if one exists?).
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Old 10-16-2014, 12:23 PM   #5
Bigger Al
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Old 10-18-2014, 11:04 AM   #6
Chapman87 OP
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For replacing the timing chain, what related parts should I replace?


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Old 10-18-2014, 05:55 PM   #7
dbarale
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Replace 12053A and 12053B at the same time.
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Old 10-18-2014, 06:34 PM   #8
Chapman87 OP
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Replace 12053A and 12053B at the same time.

Thank you, I thought there were more parts then that but I do not remember what the shop recommended. I will talk to them on Tuesday.
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Old 10-18-2014, 06:39 PM   #9
16VGTIDave
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don't forget 12053. And possible 39132 if it is worn.
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Old 10-18-2014, 06:41 PM   #10
tntmo
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I would suggest that you inspect the timing chain guides and replace them if needed. 12053A probably requires you to remove the head to replace it, so if it's bad you'll need a head gasket. 39132 looks like a roller bearing, never seen a cam chain system run one of those but take a good look at it and replace it if it's suspect.

I'd suggest getting a side cover gasket, cam chain tensioner gasket, possibly replace the entire tensioner if it isn't too expensive.
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Old 10-19-2014, 03:55 AM   #11
wiggywildwildwest
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if you can, break the chains and join the new one to the old one. it's pretty easy (with the valves closed and the plug out) to just pull the new one through with the old one. means you don't have to take the flywheel etc. off too.
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Old 10-19-2014, 07:06 AM   #12
Chapman87 OP
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if you can, break the chains and join the new one to the old one. it's pretty easy (with the valves closed and the plug out) to just pull the new one through with the old one. means you don't have to take the flywheel etc. off too.
What type of chain tool do I need for that?
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Old 10-19-2014, 10:27 AM   #13
tntmo
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What type of chain tool do I need for that?
I'm not sure about this. Most Japanese bikes have an "endless" style cam chain. I don't know that you could re-use a link after you break it, and I haven't seen a link for sale. KTM does their cam chains this way, so I know some bikes do. Guess it's something to look into.
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Old 10-21-2014, 05:37 AM   #14
jules083
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I'm following this thread, mainly because my klr250 top end is louder than I think it should be. Mind posting pictures of the re-build?
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Old 10-21-2014, 02:55 PM   #15
Chapman87 OP
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I'm following this thread, mainly because my klr250 top end is louder than I think it should be. Mind posting pictures of the re-build?
Yeah I will. I cant believe the lack of info or even builds on these bikes, they were made for a long time with no changes!
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