KLR250 thread

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

  1. wsdbikes

    wsdbikes New Max is Mad

    Joined:
    May 8, 2007
    Oddometer:
    1,282
    Location:
    PNW
    Surplus store-$20.00
    Drill 4 holes and there you go.

    provides a ton of storage and a platform to carry other stuff.
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    #81
  2. ECDLTF

    ECDLTF Adventurer

    Joined:
    Feb 21, 2010
    Oddometer:
    49
    Thanks for the tips regarding the adjusting the valves. How difficult is it for a novice? The bike has 1600 miles on it and is in very good condition. The starting issue is probably due to my lack of experience as I'm new to this bike and riding in general. Have often does it have to be done? Thanks again.

    #82
  3. 1994klr250

    1994klr250 Been here awhile

    Joined:
    Aug 16, 2007
    Oddometer:
    851
    Location:
    SE michigan
    The Ricochet skid plate offers much more protection vs the stock skid plate, I've had mine for about 1 year on my bike. It covers the entire bottom side of the engine and has some large ears that extend out on each side to protect the water pump. Turbo city has one but the price is almost 3 times that of the ricochet skid plate. http://www.turbocity.com/product_info.php?cPath=69_75&products_id=691

    For the price and protection the ricochet offers its a great deal. Here's some pictures.

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    #83
  4. 1994klr250

    1994klr250 Been here awhile

    Joined:
    Aug 16, 2007
    Oddometer:
    851
    Location:
    SE michigan
    The valve adjustment shouldn't be a problem for a novice just a few basic hand tools and a few hours. The service manual shows every 3,000 miles they should be checked. I check mine every year in the spring so I know I'm good for the rest of the year. Bottom half of this page shows how to check the valves http://home.earthlink.net/~klr250informationexchange/toolkit.htm
    #84
  5. ECDLTF

    ECDLTF Adventurer

    Joined:
    Feb 21, 2010
    Oddometer:
    49
    It has 1600 miles right now. I think that I'll wait a little longer before I take on the valve adjustment job. Thanks for the help and the link. Have a good evening.


    #85
  6. BerndM

    BerndM Shiftless One

    Joined:
    Aug 9, 2007
    Oddometer:
    1,614
    Location:
    Near Disneyland, in SoCal.
    Here is a shot of my 1986 KLR250. All stock parts, never been apart.

    Attached Files:

    #86
  7. Gvilleracer

    Gvilleracer Been here awhile

    Joined:
    Dec 7, 2009
    Oddometer:
    149
    Location:
    Jax, FL
    Hey everyone, I'm new to the KLR250 crowd.
    Picked this up on Sunday off Craigslist. Started to regret it.... So me and a freind tore it down.
    Now the re-build begins.

    Mechanically and electrically, I think we lucked out; but, asthetically, this thing must have sat at the bottom of an ocean!

    looks good from a distance
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    BUt on closer inspection.
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    Two beers after taking the above photos.......
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    There is my freind, Cam, this is our first DS re-build. So we wanted to start with an easy one, hope we did. We will try to keep updates coming as we sort the bikes issues!
    #87
  8. MudWalker

    MudWalker Long timer

    Joined:
    Sep 19, 2005
    Oddometer:
    3,126
    Location:
    Lake George
    This is what my KLR250 looks like most of the time I have owned it, now 10 years....wow time flies. I have put over 7000 miles of off road work on the poor thing and I just can't seem to break it. It's old technology yes but it is a very effective tool when climbing around in the woods. It will go for road rides as well although I'm not sure it's happy going fast.:lol3

    If you can get a good running one, buy it, mine has never let me down.
    #88
  9. wsdbikes

    wsdbikes New Max is Mad

    Joined:
    May 8, 2007
    Oddometer:
    1,282
    Location:
    PNW
    Looked about right for a good KLR . I assume it wasnt actually running thus, tearing it down?


    #89
  10. XDragRacer

    XDragRacer Long timer

    Joined:
    Mar 25, 2009
    Oddometer:
    3,816
    Check Post # 49 above; Utah Sport Cycle, same as otherwise-branded bash plates . . .

    I elongated the oil drain hole on mine for more direct draining into the catch pan and less onto the bash plate:

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    #90
  11. Gvilleracer

    Gvilleracer Been here awhile

    Joined:
    Dec 7, 2009
    Oddometer:
    149
    Location:
    Jax, FL
    Yup, not a runner, but the price was right. Well it would fire but stall within seconds and fuel was pouring out the overflow, ya for stuck float valves!
    It has, like most barn finds, spent some time in storage with old gas in the carb. Judging buy the build up I found in the carb bowl, I would say it sat for close to one year.

    My freind scored a bucket of carb/parts cleaner from work last night. The carb is getting dissasembled and cleaned tonight. Of course our carb has already ben tampered with I notice the brass plug is already drilled out and the plastic choke cable fatener thing is gone. So, now i have to find a way to secure the choke to the carb.

    Things coming in the mail so far: via EBAY.....FTW
    1. New brake and clutch levers.
    2. new choke lever for left handlebar control, from KLR650
    3.new throttle tube for a 96 KLR 250...hope it works.
    4. UNI dual stage filter

    hopefully this stuff will arrive shortly and we can start reassembly.

    Cam stopped at cycle accesories last night:
    1. renthal grips
    2. new NGK spark plug

    While we are waiting for these parts to arrive we will be doing a lot of grinding sanding and painting! hope to clean the frame up real nice :D
    #91
  12. tankster64

    tankster64 Adventurer

    Joined:
    Nov 1, 2009
    Oddometer:
    24
    Location:
    Jackson, TN
    I got one last friday. 05 3400 miles, seems to be in great shape.
    First ride on Saturday. This is my first dual sport bike. Had big fun. Road, trails, sand pits, hill climbing. I think I am going to be very happy with the 250.
    Tried to upload a picture. But no luck.:(:
    #92
  13. alansz400

    alansz400 Long timer

    Joined:
    Aug 10, 2009
    Oddometer:
    1,264
    Location:
    Loudonville ohio
    My front brakes on my 2001 didnt work real good when I bought the bike about a month ago. I could pull the handle all way back to the grip if I pulled real hard. I tried getting the air out of the system even used the vaccum pump to pull the air out but it didnt seem to help. I read on some other sites that other guy have the same problem so I bought a complete used front brake system off ebay from a DR650. I was going to put the master cyl. and the line on but thought I would try the master cyl. first. after bleeding the system I now have 100% better feel in the handle and alot more stoping power. I can lock the front wheel up on dry black top. The 650 banjo bolt also has alot bigger hole in it. Hope this helps. Alan
    #93
  14. Gvilleracer

    Gvilleracer Been here awhile

    Joined:
    Dec 7, 2009
    Oddometer:
    149
    Location:
    Jax, FL
    ^^^

    Do you happen to know if you changed piston sizes with this swap?

    This is a great find!
    But, i would love to know if the feel is much better because your old one was just worn out, or if the dr650 master pushes more fluid?

    Either way, great find, this will be on my list, the KLR im rebuilding couldn't even lock its front brake coming backwards down the ramp form the bed of my truck....LOL!
    #94
  15. wsdbikes

    wsdbikes New Max is Mad

    Joined:
    May 8, 2007
    Oddometer:
    1,282
    Location:
    PNW
    My KLR never went fast enough to need a front brake.:lol3 :lol3 :lol3 :lol3
    #95
  16. alansz400

    alansz400 Long timer

    Joined:
    Aug 10, 2009
    Oddometer:
    1,264
    Location:
    Loudonville ohio

    I took the 250 master cyl. apart and the bore looked good as did the rubbers on the shaft. (The bike only has 5000 miles on it) I was going to buy the parts to rebuild the klr one but it was 30$.:eek1 I looked at the bike shop and it looks like the master cyl. on any brand of dual sport will work as long as it has the brake light switch. I bought the DR650 one so if it didnt work I would have parts for my DR. Not sure about the bore size.
    #96
  17. Gvilleracer

    Gvilleracer Been here awhile

    Joined:
    Dec 7, 2009
    Oddometer:
    149
    Location:
    Jax, FL
    Ok,so here's how the weekend went down.
    Every time one of us said "There is no need to take that off"...the other would say "but it would be easy, c'mon, its two bolts..."

    which lead to this!
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    Yes, we were very proud to display our victory.....let me explain the carnage...

    when we left off last time, the motor was still in as well as the front end and swing arm.
    The plan was to tape everything off a spray bomb our little trail beater.
    Well, Cameron!!!!! wanted to do the job right...blah blah balh
    So, we decided to pull a few more things(I knew no good could come of this)

    Out comes the motor along with a few broken bolts!
    The bolts that hold the plastic cover over the front sproket broke when I looked at them!
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    Eww
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    Well, with this great feat accomplished. Cam took a moment to ponder the possibilties..
    Who says a 250 cant compete at the salt flats!
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    Off with its head! Bearings are in great shap, so a clean and re-pack is all thats needed here.
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    Now, this is when tools started flying out of the garage, into streets, and children playing near by learned new vocabulary!
    Time for the swing arm to come out!
    Easier said than done when working with a rusted relic that was obviously dragged behind Noah's Ark!
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    After many beatings with a sledge!
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    30 min and two cans of PB Blaster later...
    Dude, I'm telling you I soooo moved it and inch!!!!
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    I did what I could to save the threads, but I just cant resist a high grade steel!
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    Its def muffed. So I ordered a new one off ebay for $4.95 that will arrive soon, I hope.
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    Cam really wore himself down beating this one out!......hehehehehehe
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    PS, if anyone doesn't already know (we didn't) here is where your rear adjuster is on the shock. under a small plastic cover.
    And 5lbs of soil that has cured to the consistency of a clay brick, if your bike is like ours!
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    So, this is what lead to the display of grousome destruction hanging from the tree like 3rd-world lawn art!
    We got some sort of satisfaction from showing the whole three cars that past by our acheivment... We are man!

    Just in time... my wife showed up to help the two gorrilas re-assemble the crippled machine.
    And she comes bearing gifts.....Subway $5 foot-longs
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    Now don't start singing the commercial tune, stay focused here!

    After we wipped out a few subs, we got back to work!
    Christa taped up the rear rim for paint, covering the rim and brake areas. Since the spokes and inner hubs will be flat balck.
    I started painting up side covers and little what-nots.

    So, wifey seeing that all was going fine decided to go home and do somethig of greater value (closet sorting!...Ooooooo)

    and Cam...where is Cam...

    Captain Bolt Snapper Attack!!!!!
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    After much air grinding, sanding, cleaning, it came out real nice.
    But, we have picked a paint that was a tad to Silver, not the aluminum look we anticipated.
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    So, we got a few other things primed and painted; but, things moved so fast we failed to take pics!

    Dad actually finished rebuilding our carb and gave that to us.
    Knowing that we were going to be runnig the airbox mod and a Jardine pipe. Which is quiet but slightly better flowing than stock.
    He decided to fatten up the low speed circut from closed to 1/3 throttle.
    Adding some fuel here will keep response and low end torque where it should be, as well as cruising temps low.
    By having a little extra unburnt fuel to pull heat out. I know this sounds wastefull but...
    I can't stand lean-pops on decel, so he wanted to be sure their wern't any!

    We spent a few minuets picking at dad for using Harley parts in our carb.
    He found that the rediculously lean pilot jet from a 883 Sportster could give our 250 the flow we wanted with our mods.
    That, and it was laying there and ours was clogged beyond beleif! So, I'll let ya know how it runs!

    Then a sound rolled into the garage with a presence that could only be created by the clanketty thump of a classic British big twin.....
    Or Christas' GS500 with a blown out Yosh pipe, LOL. (its bark really is much more respectable than its bite)
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    Wife had to stop by to make sure that we ate a healthy meal!
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    All in all we had great weekend and enjoyed working on the bike with freinds and family!
    #97
  18. Hannda

    Hannda Short, fat, bearded, slow

    Joined:
    Apr 27, 2005
    Oddometer:
    31,584
    Location:
    Not yet far enough away from town
    If it's hard to start do the valves now. They were probably not done at the 500 mile service - probably didn't have a 500 mile service if you're finding it hard to start.
    #98
  19. ECDLTF

    ECDLTF Adventurer

    Joined:
    Feb 21, 2010
    Oddometer:
    49
    Thanks for the tip. It's starting fine now. It was more my lack of experience and not the bike. I ordered a KLR600 manual and just need to buy the supplement for the KLR250. I won't adjust the valves until I get a little more familiar with the operation of the bike. I just learning to ride and familiarize myself with the bike. Thanks again for the help. Have a good evening.

    #99
  20. HandKPhil

    HandKPhil Been here awhile

    Joined:
    Oct 26, 2009
    Oddometer:
    579
    Location:
    Southeast Michigan
    Hi,

    Can anyone tell me the torque values for the countershaft sprocket bolts and the rear sprocket bolts? I'm not lazy, it's just that my service manuals have not arrived yet:D

    My bike's an '03 KLR 250, by the way.

    Thanks,
    HandKPhil