The Mods Might Begin ! ! ! - KLR650.NET Forums - Your Kawasaki KLR650 Resource!

Marty · 01-23-2006, 05:54 PM

I've been talking to a few other KLX250 owners via e-mail. They have been doing some low-cost mods to their KLX's and getting interesting results.

The jury is still out on a few things, but it looks like some drilling, a bit of jetting, some sprocket changing, a couple of plugs and the KLX250 can be transformed into a ripping 250cc four stroke thumper!

Seems as though both of them are going in different directions and coming to the same destination. One is going with de-smog-ification of the little motor, the other with jet changes - same result. The little motor wakes up and starts to show it's heritage!

A fellow just sent me an e-mail on the jetting / exhaust changes he has done. Seems as though when he drilled out the end baffle in the muffler the bike started surging. Then he went to a main jet #125 and is having trouble keeping the front tire on the ground with his 13 / 45 gearing. This is all sounding quite interesting.

Stay tuned for more information and pictures as they come available!

backspinnn · 01-23-2006, 10:23 PM

The KLX300 I got last weekend is jetted with an FMF pipe and decorked. It rips compared to the sherpa I had. Now that I figured out how to kick start it, I can probably take it off on some adventures. It looks exactly like the KLX250S minus the decals and legal bits. I feel like I got the deal of the century on that bike. I will post some pics soon...

Moat · 01-24-2006, 03:04 AM

Quote:

Originally Posted by Marty

... he drilled out the end baffle in the muffler ...

Hi, Marty - Todd (bmwld)? Over on Todd's KLX250 thread at ADVrider, somebody noticed the muffler's outlet size on U.S. versions to be considerably smaller than an Aussie KLX. Maybe a "group buy/ship" for the Aussie muffler is an idea.

My concern is if drilling the baffle might render the spark arrestor inoperative (a legal and environmental safety concern). Or if the Aussie muffler even has a spark arrestor? I wonder if anybody knows...?

Nothin' much to add, really - just thinkin' aloud... and

Marty · 01-24-2006, 05:21 AM

Moat,

I guess great minds think alike! I've asked BMWHD the same question. Am waiting for a response from him BEFORE I hit the pipe with the drill.

Thus far I am sure I am going to go with a 13 tooth countershaft sprocket - from what I am reading, that is almost mandatory!

Perhaps later, a 45 tooth rear sprocket will find it's way onto the bike.

KDX200 snorkel for the air box

Drill out pilot jet screw

Needle from a KLX300

122 main jet

From chatting with both Todd and Tony, they are getting great results from these mods to the KLX250S.

I'm happy with the way the bike runs, it's adequate for me - most of the time. Even though I'm 58, I still enjoy having fun at times.

Moat · 01-24-2006, 06:42 AM

That's great... a handful of easy and cheap (the best kind!) mods, netting such noticable results.

Man... sounds like fun!

Let us know if the 13t makes it seem "busy" at highway speeds (although it sounds like it's overgeared, if anything - stock).

a16tony · 01-24-2006, 08:29 AM

Radar is up and my ears are burning. Hey Marty

I made it over here. I get some sun today, so I can abuse that 125 jet. Reports to come.

Marty · 01-24-2006, 11:10 AM

a16tony,

Welcome on over to klr650.net and the KLX section. We'll do all we can here to make your stay a long and pleasant one. Thanks for taking the invite.

I just got back from my nemesis road FR-572. This road is loaded with whoops, mud, sand and my all time unfavorite . . . .

S U G A R - S A N D ! ! !

We're not talking your typical sand, this is the heavy duty industrial stuff that will swallow a 4x4 truck! It's cruel. About it's only saving grace is that it is soft when you dump the bike in it! :lol2:

Without a doubt, the bike needs to be geared lower - a 13 tooth countersprocket is simply the starter. I am now thinking seriously of a 45 tooth rear sprocket!

Even in 1st gear, the bike bogs down so much, you lose headway. It gets so loaded that you have to get down off the pegs as you lose all stability to plow through the stuff.

There is a short stretch of road back to town with a 55 mph speed limit on it. Stock gearing will run 6th gear at 65 mph indicated. If you click down to 5th gear, the bike is a lot more lively and will accelerate easier and it just sounds a whole lot happier.

So, I'll probably rather switch than fight - the sugar sand that is!

scat · 01-24-2006, 10:12 PM

Hey Marty I found you

,Been browsing around the site ,looks good and good info as well, chat with you later

bmwhd · 01-25-2006, 06:05 AM

I can't say enough about how much MORE fun the bike is after the carb work and drilling the exhaust.

I don't know about the impact on the spark arresting ability after drilling. The rear baffle plate doesn't look like a screen on my bike as it does on the pics of the Aussie bikes. No one is going to be able to tell you've done the mod just by looking.

The increase in noise is very small. Just a nice little extra growl on hard throttle. Sounds the same at low to mid RPM.

01-23-2006, 10:23 PM	#2
backspinnn A Regular Super Cool Since: Dec 2004 Postings: 235	The KLX300 I got last weekend is jetted with an FMF pipe and decorked. It rips compared to the sherpa I had. Now that I figured out how to kick start it, I can probably take it off on some adventures. It looks exactly like the KLX250S minus the decals and legal bits. I feel like I got the deal of the century on that bike. I will post some pics soon... __________________ Chris N Lowry Crossing, TX 07 450 EXC 03 FZ1

01-24-2006, 05:21 AM	#4
Marty KLR-a-holic KLR Enthusiast Super Cool Since: Jan 2004 Locale: Just South of The Ocala National Forest Postings: 5,753	Moat, I guess great minds think alike! I've asked BMWHD the same question. Am waiting for a response from him BEFORE I hit the pipe with the drill. Thus far I am sure I am going to go with a 13 tooth countershaft sprocket - from what I am reading, that is almost mandatory! Perhaps later, a 45 tooth rear sprocket will find it's way onto the bike. KDX200 snorkel for the air box Drill out pilot jet screw Needle from a KLX300 122 main jet From chatting with both Todd and Tony, they are getting great results from these mods to the KLX250S. I'm happy with the way the bike runs, it's adequate for me - most of the time. Even though I'm 58, I still enjoy having fun at times. __________________ Marty The "Doomeister" KLEX-500 (project) KLX-331S KLR-650 A18 DL-1000 K6 ~ How come you never see a motorcycle parked in front of a psychiatrist's office? ~

01-24-2006, 06:42 AM	#5
Moat A Regular Super Cool Since: Jul 2005 Locale: Mid-Mitten Postings: 74	That's great... a handful of easy and cheap (the best kind!) mods, netting such noticable results. Man... sounds like fun! Let us know if the 13t makes it seem "busy" at highway speeds (although it sounds like it's overgeared, if anything - stock). __________________ Bob - '97 KLR250 - '01 YZF600r

01-24-2006, 08:29 AM	#6
a16tony A Regular Super Cool Since: Jun 2005 Locale: Everett, WA Postings: 31	Radar is up and my ears are burning. Hey Marty I made it over here. I get some sun today, so I can abuse that 125 jet. Reports to come. __________________ Tony Everett, WA 08 KLR650 02 KLR650 06KLX250S

01-24-2006, 11:10 AM	#7
Marty KLR-a-holic KLR Enthusiast Super Cool Since: Jan 2004 Locale: Just South of The Ocala National Forest Postings: 5,753	a16tony, Welcome on over to klr650.net and the KLX section. We'll do all we can here to make your stay a long and pleasant one. Thanks for taking the invite. I just got back from my nemesis road FR-572. This road is loaded with whoops, mud, sand and my all time unfavorite . . . . S U G A R - S A N D ! ! ! We're not talking your typical sand, this is the heavy duty industrial stuff that will swallow a 4x4 truck! It's cruel. About it's only saving grace is that it is soft when you dump the bike in it! :lol2: Without a doubt, the bike needs to be geared lower - a 13 tooth countersprocket is simply the starter. I am now thinking seriously of a 45 tooth rear sprocket! Even in 1st gear, the bike bogs down so much, you lose headway. It gets so loaded that you have to get down off the pegs as you lose all stability to plow through the stuff. There is a short stretch of road back to town with a 55 mph speed limit on it. Stock gearing will run 6th gear at 65 mph indicated. If you click down to 5th gear, the bike is a lot more lively and will accelerate easier and it just sounds a whole lot happier. So, I'll probably rather switch than fight - the sugar sand that is! __________________ Marty The "Doomeister" KLEX-500 (project) KLX-331S KLR-650 A18 DL-1000 K6 ~ How come you never see a motorcycle parked in front of a psychiatrist's office? ~

01-23-2006, 05:54 PM	#1
Marty KLR-a-holic KLR Enthusiast Super Cool Since: Jan 2004 Locale: Just South of The Ocala National Forest Postings: 5,753	The Mods Might Begin ! ! ! I've been talking to a few other KLX250 owners via e-mail. They have been doing some low-cost mods to their KLX's and getting interesting results. The jury is still out on a few things, but it looks like some drilling, a bit of jetting, some sprocket changing, a couple of plugs and the KLX250 can be transformed into a ripping 250cc four stroke thumper! Seems as though both of them are going in different directions and coming to the same destination. One is going with de-smog-ification of the little motor, the other with jet changes - same result. The little motor wakes up and starts to show it's heritage! A fellow just sent me an e-mail on the jetting / exhaust changes he has done. Seems as though when he drilled out the end baffle in the muffler the bike started surging. Then he went to a main jet #125 and is having trouble keeping the front tire on the ground with his 13 / 45 gearing. This is all sounding quite interesting. Stay tuned for more information and pictures as they come available! __________________ Marty The "Doomeister" KLEX-500 (project) KLX-331S KLR-650 A18 DL-1000 K6 ~ How come you never see a motorcycle parked in front of a psychiatrist's office? ~

01-24-2006, 10:12 PM	#8
scat Occasional Poster Super Cool Since: Jan 2006 Locale: Everett WA Postings: 6	Hey Marty I found you ,Been browsing around the site ,looks good and good info as well, chat with you later __________________ Scott Ride Safe Everett WA 06 KLX250s

01-25-2006, 06:05 AM	#9
bmwhd Active Member Super Cool Since: Dec 2003 Postings: 526	I can't say enough about how much MORE fun the bike is after the carb work and drilling the exhaust. I don't know about the impact on the spark arresting ability after drilling. The rear baffle plate doesn't look like a screen on my bike as it does on the pics of the Aussie bikes. No one is going to be able to tell you've done the mod just by looking. The increase in noise is very small. Just a nice little extra growl on hard throttle. Sounds the same at low to mid RPM. __________________ Todd R. Grapevine, TX USA '06 KLX250S '06 FJR1300A

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