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KLR250 and Super Sherpa Main Discussion


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Old 03-06-2017, 03:42 PM   #1
wesson123970
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Default 250 blown up?

Hi guys,

Well, i think i've probably goofed big time buying an '01 KLR 250. I only paid $250 for it thankfully. The guy that had it said it had lost compression over time and wouldnt crank.The guy really talked in circles - Couldn't tell if he was dumb or just wanting to screw me or both. i did get from him that he had been on the interstate a lot and it wasn't fast enough. Upon inspection i noticed that it had 0 compression...turned over like the plug wasnt in,but it was in!. When i checked the valves, i found they were all 4 very tight - couldnt get a feeler guage in any of them. Adjusted them all, cleaned the carb and put in fresh gas. Finally it cranked, but didnt sound right - almost like a 2 stroke. I let it warm up, but i could barely give it any gas w/out it bogging. I was able to kind of keep juicing the gas a little more each time to go up to fairly high rpm (nowhere near enough to blow it - i've ridden for 30yrs). It was smoking and sounded kind of 2-stroke like to me. Then it just cut off and wouldnt crank back. I noticed when i tried to crank it again, it felt like it had before - no compression. I waited about 10 minutes and tried again. Same thing.
Anyone know what i'm looking at here? I really think this guy dogged it on the interstate and it got way too hot. Warped head? Really regretting i didnt wait and get one that was running. Had to take a chance!
Any help/ideas are greatly appreciated!
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Old 03-10-2017, 11:30 AM   #2
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Default Re: 250 blown up?

Sounds like a very worn out cylinder

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Old 03-18-2017, 01:25 PM   #3
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Default Re: 250 blown up?

Try kicking the bike over with the Kawasaki Automatic Compression Release (KACR) spring removed from the exhaust cam. The KACR normally serves to relieve some compression when starting by cracking open one exhaust valve. This may help get a clearer picture of what compression you have, or further confirm a lack of compression. If you haven't confirmed correct camshaft timing, do that while pulling off the KACR spring (a dental pick is helpful in this task). With results of a compression test with the KACR disabled by removing the spring, it may be time to dive in and check out the piston, rings and valves.

If you get into it to inspect and measure the cylinder, you can inform your search looking at options for an overbore piston. Kawasaki has or had 2 sizes of slight overbore piston for addressing a worn cylinder, Wiseco makes 2 overbore sizes with slightly increased compression (11.5:1 as opposed to 11:1 stock) listed for the KSF250 Mojave ATV which shares many engine parts with the KLR250, and from Cycle Works Racing in Pennsylvania there is a 280cc piston (11.8:1), also listed for the KSF250 and is manufactured by JE Pistons. I have the Cycle Works Racing 280cc setup and enjoy it pretty well.
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Old 04-26-2017, 07:39 AM   #4
laylow
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Default Re: 250 blown up?

I removed the KACR system completely as it was not needed and to me it was just another weak link in this motor.. I replaced my piston and rings as well.. the lil klr is a awesome bike and is very capable of doing highway speeds once all the weak links are taken care of... If it's running now I would do a compression check... if the valves where that tight the motor was probably ran too lean and it cooked the piston and rings... possibly worn the cylinder as well.. when I replaced my piston I went with a slightly bigger one from Wiseco (as kidflyr mentioned) and had my cylinder bored... I also had issues with my valves and I replaced them with Kibblewhite valves...there was some other issues too but for a bike that was running for $950 and made me $12,000 it is a definite keeper
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Old 05-02-2017, 08:27 PM   #5
TownsendsFJR1300
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Default Re: 250 blown up?

Sounds like the top end is toast and a full inspection needed.

We already know it has little to no compression.

Doing a leak down test on the engine (before dis-assembly) would give you an idea of what's going on inside the engine...

I see the head coming off at a minimum.
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