It seems that most of them have the mid 90's model KLX250. Some of them have been reading about the KLX300 barrel direct bolt-on being done over here with the KLX250s and are trying it on their older models which apparantly have a smaller case opening. Seems that a few of them don't learn that the crank case opening is about 4mm too small until they try to install the 300 barrel! OMG!

Now all of them pass off the direct bolt-on we've been doing as 'myth.' Further, some of them are saying that anybody who says it can be done hasn't tried it.

There must be a year when kawasaki changed the manufacturing process on the KLX250 making the cases a bit more universal. Does anyone have the trivia on that?

 

as far as I know that site hasn't been updated for a few years

 

I saw some fairly recent posts their today. Oh well...no big deal. I just would have hated to be the one to find out about the size difference though. Aparantly the the case opening was given some wiggle room since their bikes were built.

 

Site last updated
22nd Aug 2005

 

Yeah, that would really suck to take everything apart and get to the point of installing the cylinder only to find that it didn't fit [:@]

 

I've figured it out. 1997 and older models of KLX250 had smaller openings for the barrel. Don't know the reason why, but maybe the case is now universal for the KLX300 and 250. Nothing like a little streamline of the production process.

I'm probably boring you guys to tears, but this sort of thing has always put me in the curious mode. [8D] What can I say, I'm easily entertained.[&:]