Just got my bike back from the dealer with the 300 kit installed, runs great! Pulls wheelies and has alot more low and mid range. They also rejetted the carb and tuned with the exhaust machine, 132 main jet was installed and they adjusted the air screw. Iam noticing a ticking noise that I have read about in the forum. It's not real loud but noticable. The lead mechanic at a large dealer installed the kit, I have alot of faith in the guy. He has 20 years of bike mechanic exp. I have not called them yet about the noise because Iam waiting to see if it is the cam chain, and waiting to see if it adjusts itself. I hear it more from the fuel petcock side of the bike. Again not loud but I can hear it, but I do not hear it while riding the bike only when standing next to it. Bike runs great.Who knows, it may have made this noise before but not noticed, now I am just looking to make sure the repairs are ok. The bike has 850 miles on it. He also said if I wanted the heads ported and polished it would really boost power, this would be less than $200 for this. He said it would be like adding another 50 cc's. He has already done the 300 kit and ported and polished another klx250s for one of the employees son's . When I take it for my valve adjustment in a couple thousand miles Iam getting this done.

 

Good to hear. I'm skeptical about a port and polish making that much difference, but am anxious to hear your results. I guess a good way to measure it is get a before and after dyno run.

You would be in absolute nirvana if you added a pumper to that setup

 

Good going dmar, nothing like a little more displacement!

 

Does the 300cc kit come with the head along with the jug? So matching the ports ie porting/polishing should be minimal right? Question again, what is the piston size, the piston to bore tolerance, stroke, and rod length? For the 300cc kit.

 

Is the cylinder coated or iron sleeved?

 

I'm considering a big bore for my KLX too. I've checked out the cast iron sleeve upgrade, and am trying to get more info on that vs. boring my stock cylinder and re-coating it. Which route did you take and what lead you to go that way? Who's the dealer that did the work?

Thanks for any info you can provide.

Bill

 

It's just the jug, piston, gaskets, rings, pin, and clips.

The stock 249cc is 72mm diameter by 61.2 mm stroke. 292cc (300 kit) is 78 mm piston, same stroke. The 331cc uses an 83mm piston, same 61.2 mm stroke. The 300 kit uses the Kawasaki stock cylinder for the KLX300, while the 331cc also uses that cylinder, but it is bored out. The place that did mine uses a nikasel (sp?) plating after boring.

It might be possible to use the stock 249cc cylinder, but it would need to be resleeved to go to 331cc, though there is probably enough metal if you just wanted to overbore to 292cc. There'd only be something like 1.5mm of sleeve left after boring the stock 249cc cylinder out to accomodate the 83mm piston, which is not enough.

 

Just to add to what Nobrakes has said, I don't think you will be saving much money by having the 249cc cylinder resleeved. I would feel more comfortable with the 300cc jug, because resleaving will make your cylinder less reliable. With the 300cc jug you will have enough material to bore out to 331cc without requiring a new sleeve.

Custom Kraft seems to do quality work. They re-nikasil the cylinder lining onceafter theybore it out...good stuff.

 

Good info, thanks. So now that the engine is oversquare, any timing/cam alterations?

So Nikasil is what is used and no sleeves. Thanks Nobrakes and Tremor for the info.

 

Yes you have one or the other. Either they plate directly on the aluminum with Nikasil or they press in a cast iron liner into the aluminum cylinder. If I have read on here right the 250S cylinder has a cast iron sleeve while the stock 300 jug is plated. (The plating method is the better of the two, less weight, better heat transfer, very hard wearing but can't just overbore like the old sleeve designs)


BTW I think Nikasil just what Honda calls their coatingkind of like saying "Kleenex" instead of "tissues" or "Jet Ski" in reference to PWC other than Kawasaki models, but the coating is pretty much the same reguardless of manufacturer. Someone can correct me on the Honda-Nikasil tie if I'm wrong.