I will take that as a compliment LOL I wasn't thinking too far ahead on the ring compressor. When I got to that point I was looking around for a big hose clamp to use, after none to be found I thought of the zip tie.

Thanks to everybody for the nice comments.
Dan

 

Great writeup Dan! I also burned off some of my engine paint with the gasket remover! That was the worst thing that came out of the entire conversion!!

 

I'll come down............ and go riding. Swapping out the cylinder was a satisfying experience, but not something I think I'd enjoy doing too often. 13t would help. but it still won't be a wheelie machine.
Dan

 

Great job Dan !!!! now you have me reaching for the phone to give Mr Blue a call.
Who needs groceries anyway.

 

OK, got the 351 conversion installed and it is running!

Was thinking about if I need to adj redline with the update. Does anyone know what the wt of the standard 250 klx piston is, year 2007 is what I got, but I don't have a gram scale.

I figured I'd just do a mathmatical equation on the acceloration of the mass and keep it the same. I don't think I'll need to peg it like I used to for those "big" climbs, but I dont' want to push it over on the HY to the ride.

I came close to a box of parts during the rebuild, so still trying to avoid that!

 

I just installed my 351 Bill Blue upgrade and kit and I just wanted to share my experience.

Some quick facts;
Bill has sold 377 of his 351 kits!
Going from a 250 to a 351 is a 33% power upgrade!
On this upgrade with a stock carb your go up 2 on the main jet and 1 on the pilot. I am in GA and have a 132 main and a 38 pilot. I have a M4 exhaust, the air box lid removed, and a Uni air filter.

I spoke with Bill a few times and he is a good guy and I would love to ride with him some day!

Trouble spots are few. I am lucky to have my riding buddy is my neighbor and that he loves to get his hands dirty. He also has almost every tool made!
The carb on the KLX is a bare to remove and re-install because it is a tight fit. I removed the metal bracket on the top of the carb that routes the throttle cables.











My engine bolts where odd because there was 4 bolts and 4 washers but the front right bolt had no washer installed from the factory and the one across had 2 washers!

Bill's 351 fits perfectly and adds power for wheelies and hills. I have had a DRZ400s and my KLX351s feels better.

Ohenry

 

I just finished my 351 build. Thanks for this thread. Here's a couple of notes.

Don't mix up the top dead center mark with the firing mark! They're close in position and easily confused. I wasted quite a bit of time with this one.

I used electrical contact cleaner to clean the base gasket. It didn't cause any damage to the paint and cleaned up the surface well.

The new wrist pin was very, very tight so I put some rubbing compound on it and ran the old wrist pin through and essentially polished the surfaces and also polished the new wrist pin. This made things fit a lot better without forcing them too much. When I phoned Bill noted that he had received some tight pins. It helps to freeze the wrist pin to get it in there.

Use a quality assembly grease like Lucas, available at most auto parts stores.

Put the fresh air block off plate on the head and the coolant outlet on the cylinder before you install them!

I wound up with a 38 pilot and a 132 main on the N1TC needle. 2 clips down with the air screw at 2.5 turns out. Starts very easily and runs crisp. I am running a Q4 with power bomb and the KDX snorkel.

This upgrade was well worth it. The KLX allowed me to get back into dirt biking on a mellow bike and upgrade it to a solid woods bike with some fun power.