Big bore kit confusion
 

Hi friends,
Need a big bore kit for a 2004 klx250s as ours has scored the bore,
all the ones on ebay have this compatibility below only, Was there a difference in the 2004 model in the block compared to other years? I cant find a 2004 upgrade kit anywhere.Suitable for Kawasaki

KLX300 1996-2003

Suitable for Kawasaki KLX300R 1997-2007

Suitable for Kawasaki KLX250 1993-1996

Suitable for Kawasaki KLX250R 1994-1996

Suitable for Kawasaki KLX250S 2005-2014

Suitable for Kawasaki KLX250SF 2009-2010
Cheers

I suggest you try using forum search first. You need "AHL" brand cylinder piston kit. Cylinder has "299" mark. You can get for ~$100 from Aliexpress directly from AHL - https://a.aliexpress.com/_omw07zj.

Thanks so much
 

Thanks

Pretty much all of the KLX250/300 since 1994 have the same cylinder/head. The main difference is that the KLX250 dual sport came out in 2006 with an electric start, where the earlier off roaders were kick start.

The AHL kit runs more like $150 to 180 usd on Amazon. It must be the 299 kit, the 292 does not fit. The kit is bolt on except for one thing. The lower cam tensioner spring cap needs to be shortened by about 4 mm, the threads on the cylinder aren't tapped deep enough. I cut and filed about 4mm off the threads and all works fine. Some comment about the AHL head gasket not lining up, but it really isn't a problem. It sticks out in the water jacket, but that likely doesn't present any problem. It just makes more turbulence in the water flow, which is good. If the water didn't get stirred up in the flow, if it was smooth laminar flow, it wouldn't cool as effectively as a turbulent flow does. Plus the water flow isn't extremely fast and high flow, so the bit of overlap into water jackets isn't really a problem.

THANKS Cancelled the 292 and ordered the 299 kit,, Out of curiosity whats the difference?

Holes in different positions, causing fit problems. Made for a different Chinese brand bike.