’07 KLX 250 Mods – OLD Bull Trailriders

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May 22, 2008 at 2:24 pm #94794

Chris
Member

So you’ve just purchased an ’07 or ’09 KLX 250 and want a bit more grunt.. Below I’ve listed mods in order on how I have done it on my Bike.

Firstly If your bike has not been de-restricted, this should be first on your list, this involves filling 2 holes in your carby slide, removing the snorkel on the airbox, this alone will give you a noticeable extra punch.

Firstly, 13tooth Front Sprocket, give you a little more zip off the mark and makes it easier to pull up the narly hills.
Pipe ditch the stock and go for an aftermarket, I went with a Staintune, not only a noticeble power increase but now I’m not mistaken for the postman anymore.

Still wan’t more power??

Well I went with the Genuine Kawasaki 300 kit, turns the 250 into a totally different beast, also dynojet kit, 128main with needle clip in 3rd position (From top).

Other Mods…

Pro Taper Bars
Heavy Duty Tubes
Michelin M12 Front and AC10 Rear Tyre
Replace Stock Blinkers with something a little more subtle.
B&B Bash plate
Barkbusters.
Unabiker Radiator Guards.
Works Connection Frame Guards.

Cheers

Chris.

October 31, 2008 at 11:42 am #104771

The Mekon
Member

Hey Chris,
I think our bikes will have to meet up sometime.
Though I have bought a KLX450, I like the 250 so much I am keeping it.
Mine has a similar list of modifications, 300cc, Staintune system, Dynojet + all those minor “free” mods. Also put in .42 racetech fork springs – made a big difference to the front.

here is a summmary of my bikes weight loss:-

KLX weight loss
I have checked out all the parts I have removed and made some calculations. I weighed the parts in plastic bags and I have listed the main bits, though there are some minor brackets/bolts etc in each bag.

Removed from KLX

Headlight/instruments/brackets/blinkers/speedo cable 3.2kg
Rear Rack/blinkers/fender extension 1.6kg
Fan/Pillion pegs/de ice circuit/helmet holder/chain guide+guard
Rubber cover/sidestand switch/etc 1.9kg
Original exhaust sytstem 4.8kg
Ignition Barrel 0.6kg
Fuel tank 2.3kg
Original sprocket 42T 0.7kg
Mirrors 0.5kg

Total 15.6kg

Replacements

Headlight 0.6kg
Sprocket 0.4kg
Staintune full system 3.1kg
Clarke tank 1.7kg
Vapour trail tech speedo 0.3kg
Blinkers 0.2kg

Total 6.3kg

Meaning a saving of 9.3kg

My bike originally had a 50T Standard steel sprocket as fitted to the KLX300.
This thing weighed an enormous 1.25kg, if I were to count this the weight loss would be over 10kg.

October 31, 2008 at 11:47 am #111219

The Mekon
Member

Here is a picture for those who are keen on green.

I currently run D952 tyres which for a mug rider like me seem terrific.

The clark tank gives about 11 litres, and has the dula advantage of weight saving and not needing a key (have removed the ignition barrel)

October 31, 2008 at 11:50 am #111220

shane
Member

If you have a big poo before each ride that’s almost 500 grams as well!

Forgive me…I’m on the beers.

(Seriously 10kg off a bike is nothing to sneeze at.)

October 31, 2008 at 7:53 pm #111221

Toby
Member

What sort of mileage do you get out of 1ltrs. You guys have got me thinking twice about a 450 now, I am starting to think a kitted 250 might be the go, cheaper rego to. Arr decisions decisions.

October 31, 2008 at 7:54 pm #111224

Toby
Member

I meant 11trs, obviuosly, i am a computer gumpy to.

October 31, 2008 at 9:03 pm #104772

Dwayne O
Member

Hey Fossil,
I can squezze just under 200k out of my 8ltr tank on my 250. So that`s 25k /ltr, this should give another 65- 75k with another 3 ltrs capacity I reckon. A total of 260-275ks (roughly)
My 250 is pretty much standard setup, only snorkel removed, those figures are on road commuting as well.
Cheers

November 1, 2008 at 2:39 am #111225

The Mekon
Member

Fossil wrote:

Quote:

What sort of mileage do you get out of 1ltrs. You guys have got me thinking twice about a 450 now, I am starting to think a kitted 250 might be the go, cheaper rego to. Arr decisions decisions.

The Clarke tank means I can get from the start of the dirt section on Wombeyan Caves road (there is a spot you can park your trailer there) to Limeburners Flat (66km) and back + a bit of a hoon around the Flat. Could not do this with a standard tank, even though I agree you can get 180km on the highway with the original gearing out of the standard tank.
As for a modified 250/300 instead of a KLX450 – I do not think you could come close. I looked at this option as I am keeping the 300. To make it up to 331cc + pumper carb + some additional suspension work, would have cost another $1500 – $2000 The bike might have had around 30-32hp at this stage, with a gut load of torque (that’s what I like about my current KLX)

If you bought a second hand low km. KLX250 for about $3000 – $4000, you would still need to spend at least another $3000 to make it a hard charging 331. The bike would be good, but perhaps not as good as the 450 – I will soon know.

November 1, 2008 at 3:34 am #111228

Greg
Member

I fitted Chris’s 300kit and couldn’t credit the difference 50cc to the bike, it’s a fast very capable bike and I would think with some suspension tweaking you would be faster on it in most conditions then on the 450, also the 300 wouldn’t wear you out during the course of the day like a 450.
As far as the 331 kit goes the engine is designed and built for certain loads and stress on components, the engine handles a 50cc increase because it was designed for it in the frist place. The increased stress put upon components such as piston, little end bearing, conrod, big end bearing and main bearings over a period greatly reduces life and reliability (ask Bana his DR has blown up twice)

The increase from 250 to 300 is incredible, but I think the old saying that some is good but more is not always better maybe worth considering, cost and stress on parts etc taken into play.

I keep thinking about those 720cc they sell in the states for my bike, but my bike has a HRC kit in it and that’s enough, truth is its more than I ever use or can if I was towing road trains I may do it, ha ha crash will tell you our 650 would pull road trains as they are.

TB

ps if you do it I would love to see the difference it makes, the 331 kit that is

November 1, 2008 at 7:27 am #111229

Toby
Member

I agree TB taking it to far will only compromise reliability that is why i am concerned about the 300cc kit, but i have only heard good reports. I will have to call kwaka tech guys and see what they reckon. The 250 really appeals as the are so cheap and cheap rego too, but i want something that is going to be good for long hauls as well. e.g. i am keen to do some two or three day runs up my way. and when i say two or three days i do not mean loops, i mean heading in one direction for two days then getting picked up by car, you would not believe the size of the riding area i have, it is overwhelming.

November 1, 2008 at 10:27 pm #111245

Chris
Member

Hey Mekon,

Yeah our bikes seem very similiar, I have few things still to do that hasn’t been done yet, it’s all a matter of time. I will pick your brains a bit later about the stand switch and some other things that you have done. I have to say after riding some 450’s I am very happy with the 300 and I am still not using it all to it’s potential. When that happens I may look at the 450. I like the power delivery of the 300kit, has plenty of torque and is light enough to not rip your arms off.. I need to do some suspension work and I think that after that It will go from a great bike to an awesome bike..
How did you go with the Clark tank, I have read that there are some fitment issues??
If you search for Bill_Blue, he does the 331 kits and also the braided stainless brake lines. Got the brake line off him and it made a world of difference to the stock one.

Cheers
CHris.

November 1, 2008 at 10:29 pm #111279

Chris
Member

Are you running the airbox lid, I’m not but the amount of crap I get in their is unbelievable, I was thinking of putting it back on, but drilling some extra holes and then lining it with some sort of mesh.

Cheers
Chris.

November 2, 2008 at 1:32 am #111244

Chris
Member

Fossil wrote:

Quote:

I agree TB taking it to far will only compromise reliability that is why i am concerned about the 300cc kit, but i have only heard good reports. I will have to call kwaka tech guys and see what they reckon. The 250 really appeals as the are so cheap and cheap rego too, but i want something that is going to be good for long hauls as well. e.g. i am keen to do some two or three day runs up my way. and when i say two or three days i do not mean loops, i mean heading in one direction for two days then getting picked up by car, you would not believe the size of the riding area i have, it is overwhelming.

Hey Fossil, maybe give Scott at Battyes a ring (link off front page) tell him your an old Bull, I’m sure he’s be happy to help/advise. Very knowledgeable about this stuff.

Cheers
Chris.

November 2, 2008 at 4:36 am #111280

The Mekon
Member

Hi Chris,
Yes I run the airbox lid, though I have doubled the size of the opening.
I run the lid as there is too much intake noise without it and, as you say, too much muck gets in the airbox.
The Clarke tank is not the best cosmetic finish. It does bolt straight on without any modifications.
On my 05 model I had to apply a heat gun to the shrouds to make them fit over the side bulges in the tank. 07 model owners have different shrouds and may not need to do this.
I also like the fact that this bike feels light, and is extremely tough. I have binned the bike heaps and it just does not break. In fact I wish Kawasaki had kept with a steel frame for the 450 model.
I know about the Bill Blue 331 mod of the 250 cylinder. Were I ever to want more cc, I would prefer to take the more conventional route of boring out the 300 cylinder to 83mm and then nikasil again. This is a much better job than the thin sleeve that the other method uses on the 250 cylinder. I would have no doubts about reliability in going the former way.
Still I will not need this now. I had to have the KLX450 after a short ride on my friends Yamaha 450. It can easily hoist the front wheel in 3rd gear, and the suspension is way better than the KLX250.
One of the reasons I preferred the KLX450 is that I am only average height, and can reach the ground with my feet on the KLX, but not the Honda or Yamaha.
My first dirt bike was an old Honda XL175, then a Honda XL250 degree, then the KLX250. Each bike has been a huge improvement on the last, and am hoping for a similar leap in getting on the KLX450R.

November 2, 2008 at 4:40 am #111285

Chris
Member

Yep Mekon all agreed, did you see bikebiz in parramatta are/were doing the 08 450 for 9990.00 at that price it;s a serious consideration..

Chris.
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