Took my carb off and found one of the hoses melted shut.
Is this a vacuum hose of some sort? Also while talking about melted parts, here's a pic of my airbox. Seems that the dipstick who owned this bike before me put a fmf slip-on on and rotated the clamp bolt to where it made contact with the bottom of the airbox. I just ordered a dynojet kit and will probably leave the top of the airbox off, should I worry about the hole that got melted through? On a side note, by leaving the entire top of the air box off doesn't that decrease the velocity of air coming into it? Would a larger snorkel be better? Sorry for all the questions, but I'm pretty green when it comes to carb tuning.

 

The hose is for an overflow vent on the carb. Replace it with a new piece and it just gets routed out the back of the engine case and ends up down by the shock linkage. The airbox is a bigger problem-you are going to need to seal up that hole because it will allow water to enter if you do any creek crossings. You could use some RTV or perhaps try fiberglass to patch it.

 

KDX200 snorkel is good with the DJ kit. Or just pull the stock snorkel as the DJ kit instructions say. The DJ kit is not meant to be used with the lid removed.

 

I see this mentioned a lot. Maybe clairfy which kit your are talking about...doesn't the 2206 stage 2 instruction say remove airbox lid?

 

I bought the klx250s kit #2152. I was going to get the N1TC needle, but it costs $26 (Partzilla's price) just for it. By the time you add in a couple of main jets to try, clip, etc. it was cheaper just to buy the dynojet kit. I also have an fmf powercore4 slip-on that the previous owner had for it. It wasn't installed. He had tried it, but said it was too loud and went back to the stock pipe. I also just bought a notoil air filter. I'm thinking of trying the powercore slip on. Will any power increase over the stock pipe offset the loudness? If there's not much of a noticeable powergain with the fmf, I'd rather just have the stealthness of the stock exhaust. I'm not interested in a really loud bike.

 

for the 2009 and newer klx 250s you use dynojet kit 2152

and it only mentions intake snorkel removed for the 2152 kit

 

Froggy, what is your elevation ? If your near sea level, you could use my (and MikeW's) setup for your carb. See our setup below on my signature line.

 

I'm at 1400' here at the house, but will be riding from there up to 3500, 4000,and maybe even a little higher. Probably most will be in the 1400 to 2500' range. At the moment I've got the bike all apart and will be checking the valve clearance and flushing the radiator. I already flushed the brake fluid. All the bearings (wheel and steering head) seem fine. Just waiting on the jet kit to arrive...hope it makes it easier to start...Oh, I also ordered a .018" drill to enlarge the enricher jet. It needs a new front tire, but that will probably wait till spring.

 

Ok, gotcha.. I can't offer any facts and figures for jetting with the DJ kit at the altitudes you'll be riding at. It will be very interesting to know what works for those elevation changes.. I as well as probably many others in here will have opinions on your jetting needs.. So if you ask you will receive..LOL

Veedubs is correct that the DJ kit was not developed for lid off ( this comes directly from the DJ jetting specialist.) - as a consequence, the jets provided in the kit are too lean for max power, with lid off, at or near sea level. This fact could work in your favor as you'll no doubt be setting up lean so that you don't go too fat while up @ +4k.... Food for thought...

 

This evening I checked the valve clearance and all were in spec. The left intake valve was the tightest at .0045"...couldn't fit a .005" feeler gauge under it, but a .003 and a .0015 held together just fit. Bike has 3500 miles on it and looked like it had been ridden hard so it made me feel better to check them while I had it apart. One thing I noticed was there was some type of gasket sealant on the cylinder head side of the valve cover gasket. Do I need sealant on the gasket? I'm thinking not, and could just wait and see, but if it does need it, I'd rather do it now since I have easy access to it. Just waiting on the jet kit to get here now.