engine swap

Old Aug 28, 2019 | 07:39 PM
  #1  
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Default engine swap

will a klx 250 e-start motor ft in klx 300 kick frame without any mods--?
 
Old Aug 28, 2019 | 08:18 PM
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The electrical system is very different. When the KLX 300 came out, it was just a bored out KLX 250.

Ride on
Brewster
 
Old Aug 28, 2019 | 09:57 PM
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Yeah, the motor should bolt right in. As Brewster points out you're going to have to use the electrical components from the 250 bike to insure a smooth transition. OP, where are you in this consideration? Do you have a 300 complete bike and a dead motor?...two complete bikes?...are you going to want to continue to use the e-start in the 250?...will the finished product need to be street legal? Some variables here will determine what you'll need to do a swap like that.
 
Old Aug 28, 2019 | 10:10 PM
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Red face yes I have complete and riding 2003 klx 300, motor "very" tired

Originally Posted by Brewster
The electrical system is very different. When the KLX 300 came out, it was just a bored out KLX 250.

Ride on
Brewster
thank you Brewster-- yes I counted on making a new (or addon to harness for starter) my main concern if the frame mts are the same
for a newer model 250 with a stronger watt stator and the "starter motor of course";.-- I have swapped out the cv carb for a Bill Blue tm 34mm pumper carb but It's hard kicking this thing to get started when cold---! besides this motor needs rebuilding--! so I thought I'd
find a good 250 ( with E-starter) and make the change If It's pretty much a drop in--Any more thoughts are welcome---!
george
 

Last edited by klx300; Aug 28, 2019 at 10:19 PM. Reason: answer to question of post from TM ?
Old Aug 28, 2019 | 11:32 PM
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The generator/alternator is different between the two motors and will require even more wiring changes. I believe that is what TNC was referring to. Is the KLX300 a 2002 or earlier model? A change in ACR timing would make it easier, less effort, to kick the engine over.
https://web.archive.org/web/20170516...htips/acr.html

So far, I've done about 165 ACR timing mods for folks with the KLX300.
Ride on
Brewster
 
Old Aug 29, 2019 | 02:49 AM
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klx300, if you can find a good 250 motor, see if the whole bike is also available...like a totaled crash bike that has a good engine. If you can get the wiring harness and all the electrical components from that frame, you're going to be miles ahead in that project. There are definitely some challenges in what you plan on doing, but the electrical components from the donor bike would be a huge win.
 
Old Aug 29, 2019 | 03:19 PM
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Hi guys thank you for your reply's you're both right this is late model with acr timing change but i had a kicking lever gear tooth chip don't want to go through
that again ---this is a good trail bike with lots of mods but motor is old & tired now just like the rider is getting --He wants the ease of e-start --yes I'm
looking for donor bike to do what Kawasaki should have done at factory in first place--! of course i'm on a budget more than they were I'm sure--!! by the way
let me say this is one of the better forums to get good info on than most out here--thanks again--george
 
Old Aug 29, 2019 | 06:00 PM
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You may want to consider selling your bike intact and buying an e-start 250. You would likely save money and a ton of time/headaches.
 
Old Aug 29, 2019 | 10:52 PM
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Hi lj-rubi-- yes I'm looking at all my options ---It's just that this has been such a well mannered trail bike I really hate to give up on it--
I'll be looking for the deal I can't refuse-
 
Old Aug 30, 2019 | 12:25 AM
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Another advantage your "300" has over the 250's from '09 forward is a little more suspension travel. It's what I've always liked about the '06 and '07 models. It's why I sought out one of those two models when I was buying a used one.
 
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