Hello all, I've been here on the forum for a while now researching and reading up on the KLX. I currently own a BMW F650GS Dakar and recently sold a WR450. My wife owns a XT250. I'm 41 and my wife is a novice rider so, the WR, as excellent a bike as it was, was just too much power for the riding I do these days. I wanted a light weight Dual Sport with predictable power and long service intervals. I rode a DRZ400 but it was heavy and a handful in the sand here in the deserts outside of Vegas where the wife and I ride. I contemplated a WR250 but, a KLX250 had always been in the back of my mind.

Back in the mid/late 90's a friend of mine bought a KLX250. He bought it second hand from the local Kawi dealer. It was a year or two old at the time. It was a factory dual sport model. I had owned dirt bikes when I was younger but nothing as new or cool looking as the KLX. In the early 2000's he began a full tear down of the bike down to the frame. Sadly, he was a great guy who made some really bad decisions. He passed before the bike was ever put back together. Best I can tell it must have been a Canadian import due to our proximity to the Canadian border:

https://www.kawasakiforums.com/forum...lx-250s-43617/

Ever since then I've always wanted a KLX. Based on the research above I really wanted one like my friend owned which meant a '06/'07 model. When I sold my WR recently I decided this is the time. The pickings have been (surprisingly) slim here in Vegas until I found this bike:

https://www.kawasakiforums.com/forum...looking-44589/

I ended up purchasing the bike I was asking opinions about in the thread above - A 1997 KLX300 dual sported and plated in Utah. I paid nowhere near his asking price. Still, the bike was in pretty poor shape. It did start and run well but, it was obviously well used.

First, pic's the evening I got her home:









I enjoy working on bikes as much as I do riding them and I knew I wouldn't be happy with anything less then perfect condition. I would have likely ended up going through any bike I bought to the same level as this one so, why not save one? I like the light weight of the KLX300 and kick start as well.

A quick trip to the DMV on the way back from picking up the bike and the VIN was verified, plates, registration and title issued. Great! I had no interest in riding the bike as-is so, time to get to work...

 

Geisha has to check out the new bike:





Hachi seem's happy with Geisha's assessment:



And the kid's are fighting over who gets to ride it first:

 

Teardown begins:

 

 

 

Ugh.....

 

This wiring won't do either:

 

It was advertised as "well maintained" and specifically stated "new chain" haha:

 

Well at this point Hachi was understandably tired. We both agreed it was best for him to take a break:

 

A cheap hotplate and a pot with about 2/3rd water and 1/3rd Simple Green makes a great parts washer:



All the hardware, rubber bits, etc cleaned up pretty well.