KLR250 thread

Discussion in 'Thumpers' started by Bad Company, May 10, 2008.

  1. Airvent

    Airvent Been here awhile

    Joined:
    Feb 16, 2009
    Oddometer:
    348
    Location:
    Oxford, Connecticut
    Chains should always be on the looser end of adjustment. Less wear but more chain slap noise. I always had a slight grinding with mine, IIRC the bottom slider would wear through and cause the noise. Also i bought a heavy duty o-ring chain which was too wide for the frame. I had to grind a small amount off of the frame for it to run without contact.
  2. 8gv

    8gv Long timer

    Joined:
    Nov 22, 2009
    Oddometer:
    2,524
    Location:
    North central CT
    Regarding the front sprocket slack, do you mean as you turn the shaft or in and out on the shaft? My front sprocket slides in and out on the shaft. I was initially concerned about this but have found that it causes no trouble. At this point, I have declared this to be "normal".
  3. henrymartin

    henrymartin Mr. Tourguide

    Joined:
    Sep 11, 2010
    Oddometer:
    3,724
    Location:
    South of the Great North Woods
    I replaced the bottom slider because it was worn through.

    Yes, I do mean the in and out movement. Mine does not slide off completely, but seems loose, but as you report, this might be "normal" KLR engineering :huh
  4. losercharles

    losercharles it's just a rash

    Joined:
    Jun 24, 2004
    Oddometer:
    387
    Location:
    Austin TX
    Since there isn't a dipstick to measure oil, i figure the window on right side is to serve the purpose. So if this bike is on the side stand- oil looks nearly empty. Take the bike off the stand and set upright, the oil looks to almost fill the window. Now if I start the bike, stand it upright and look at the window - looks like there is no oil. So... How the hell do you gauge this damn thing?

    Attached Files:

  5. 8gv

    8gv Long timer

    Joined:
    Nov 22, 2009
    Oddometer:
    2,524
    Location:
    North central CT
    The owner's manual says to check it with the bike held level, after it has been off for a few minutes. Anywhere between the upper and lower edges of the slot are good. Mine uses zero oil.
  6. Brash1

    Brash1 Adventurer/Goof-off

    Joined:
    Oct 31, 2009
    Oddometer:
    52
    Location:
    Bagley, Alabama
    Where's the best place to order a chain and sprocket set for my 88 klr250? Any suggestions on steel or aluminum? O-rings worth the $$$? Also needing a taillight lens.
  7. 8gv

    8gv Long timer

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    Nov 22, 2009
    Oddometer:
    2,524
    Location:
    North central CT
  8. Brash1

    Brash1 Adventurer/Goof-off

    Joined:
    Oct 31, 2009
    Oddometer:
    52
    Location:
    Bagley, Alabama
    Thanks 8gv. Are your sprockets steel, aluminum,combo or......? I think I'll order me one of those chains.
  9. XDragRacer

    XDragRacer Long timer

    Joined:
    Mar 25, 2009
    Oddometer:
    3,324
    Not to answer for 8gv; I'm satisfied with a steel 14-tooth countershaft sprocket and a stock rear sprocket. The extra torque multiplication (vs. stock gearing) makes off-roading easier, and--with the 6th gear, highway speeds are no real problem.

    My riding style and environment only; YMMV. Your bike; countershaft sprockets are affordable and easy to change (mind the chain slack); you might want to experiment and find what you like best.
  10. 3DChief

    3DChief "Moto therapist"

    Joined:
    Jun 2, 2010
    Oddometer:
    412
    Location:
    Montana
    Just got my part in the mail and bike is back up and running! :clap:clap

    `99 KLR 250 with 6,800 miles. Noticed the valves getting noisy and adjusted them at 6,700 miles. Only one exhaust valve needed minor adjustment. After reassembling, I noticed the noise did not go away. The noise got increasingly worse and was on the left side of the engine. Rechecked the valves, still in specs. Pulled the automatic cam chain tensioner and rewound the spring. Put it back in and tried it again, same noise. The spring did seem kind of weak when I tried to re-tension it. Did some research and found this is a common problem, so ordered the new part. Took about 2 minutes to install and as soon as I removed the clip that holds it wound up, it snapped into place and I knew that was my problem. Started right up and is very quiet now, can't hear valve or cam chain noise at all!

    I emailed Eagle Mike to see if he was interested in the old tensioner to tear apart and see if it was something he could improve on, but have not heard back from him, so I will keep it on the shelf for a little while just in case.

    Tim
  11. 8gv

    8gv Long timer

    Joined:
    Nov 22, 2009
    Oddometer:
    2,524
    Location:
    North central CT
    That's what I was going to say!

    My sproket in back is factory. The new steel 14t up front helps in the woods and still allows decent street speeds.
  12. Brash1

    Brash1 Adventurer/Goof-off

    Joined:
    Oct 31, 2009
    Oddometer:
    52
    Location:
    Bagley, Alabama
    How does the 14 tooth change your mpg's? Have'nt really thought about changing, I currently run a 16 tooth counter. Do you know what stock is?
  13. 3DChief

    3DChief "Moto therapist"

    Joined:
    Jun 2, 2010
    Oddometer:
    412
    Location:
    Montana
    Stock is 15T front/44T rear. You will see a decrease in MPG, but who cares? Still way over 50 MPG and it makes it a whole new bike, like you added 100 cc to it. Will still do 85 MPH indicated on flat ground with a little rpm to go, but the difference off road and less than freeway speeds makes it well worth it. YMMV

    Change the counter sprocket to a 14T, open the air box, lose the stock air filter (buy Uni-filter foam sheet, you can get 6 air filters out of one sheet for $15), adjust your jetting, and adjust your pilot screw out 2 3/4 turns and you won't even recognize it as the same bike!

    Tim
  14. Brash1

    Brash1 Adventurer/Goof-off

    Joined:
    Oct 31, 2009
    Oddometer:
    52
    Location:
    Bagley, Alabama
    Thanks 3dchiefs, you've sold me on the sprocket set-up. I've got my bike spead out all over the basement. Doing a winter re-furb:) Lookin for some ideas on a rack for the rear[​IMG]This is the old rack that I made of 1/2" emt ( broke, not beeefy enough) I will be mounting the hard box back on top and using soft bags on the sides. Any ideas? Any pics?
  15. 3DChief

    3DChief "Moto therapist"

    Joined:
    Jun 2, 2010
    Oddometer:
    412
    Location:
    Montana
    I would stick with the same design, looks good! However, try 5/8" cold rolled steel tubing or 3/4" square tubing instead. Mine is pretty simple with 1/8"x1" flat stock sides, 1/2" iron pipe at each end, and 5/16" crossbars. I also made a bag rack out of 3/4" square tubing that sits across the top of and bolts to tailbag rack that keeps the soft bags off the exhaust. It also has a rack over the tail light that holds a 2 gal gas can. The hard part about these bikes is the lack of good locations to bolt the rack to! Use your imagination and have fun with it!

    Tim
  16. Outwardbound

    Outwardbound Been here awhile

    Joined:
    Jan 17, 2005
    Oddometer:
    706
    Location:
    Strongsville, OH
    I used 1" sq thinwall for the longitudinal upper mounts, and 5/8 (IIRC) emt to connect it all together. Rather than welding it together, I brazed it: much stronger because it's a low temp process. Be carefull welding/brazing emt. The cadmium plating releases nasty gasses.
    Here is the frame test fit my my killer:
    [​IMG]

    I used plastic cutting board top and givi-case hookup hardware. Finished prod looks like this;
    [​IMG]

    I had a set of Givi E21's laying around, and the fit on pretty well. Abused them mercilessly on dualsport single track rides and they always stayed on.
    [​IMG]
  17. henrymartin

    henrymartin Mr. Tourguide

    Joined:
    Sep 11, 2010
    Oddometer:
    3,724
    Location:
    South of the Great North Woods
    Nice!!!!!:clap
  18. Brash1

    Brash1 Adventurer/Goof-off

    Joined:
    Oct 31, 2009
    Oddometer:
    52
    Location:
    Bagley, Alabama
    3Dchief and outwardbound, appreciate the advice. I'll post up some pics when I get it done.
  19. bennyprofane

    bennyprofane grasshopper

    Joined:
    Aug 3, 2010
    Oddometer:
    24
    Location:
    Ann Arbor, Michigan
    Nice home built rack!
    I'm in the process of getting my 250 sorted for some light touring/ commuting with a set-up that looks a lot like Brash1's. My worry with my/his arrangement is that the turn signals are largely obscured. Looks like you have a pretty nice solution. Could you provide some more pic/ info?
    Cheers!
  20. Moezilla

    Moezilla Velocity Joint

    Joined:
    Oct 30, 2009
    Oddometer:
    193
    Location:
    Ozarks
    Posted this up in Parts a while ago but got nothing...

    Anybody got a set of stock links for an 05? I have a lowered bike I want to raise back up.