[align=center]Frequently Asked Questions
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Disclaimer: While all due care has been taken in the compilation and editing of these FAQs, you attempt any of these additions, modifications or maintenance work at your own risk. If you doubt your abilities to perform any of the work discussed in this FAQ, you are strongly advised to consult a professional mechanic to carry out the work for you. No responsibility or liability is accepted for any information contained in these FAQs. This FAQ is a joint effort by members of this forum and is not endorsed by Kawasaki Motorcycles.

Having said that, with the right tools, a willingness to learn and a modicum of patience, you should be able to easily perform most of the work discussed here by yourself. If you have further questions, don't hesitate to post them to the appropriate forum.

[align=center]!! Under Construction !!


[/align][align=center]NEW UPDATE AS OF 4/15/08
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Here are a few more quick links to great information. Thanks Nobrakes for the help.


KLX250S Section Sticky Thread Index

New Members Start Here: [ul][*] Forum Rules Reminder: https://www.kawasakiforums.com/m_61283/tm.htm[*] Welcome Message from the Moderator : https://www.kawasakiforums.com/m_32128/tm.htm[*] More Frequently Asked Questions: https://www.kawasakiforums.com/m_32156/tm.htm[*] KLX Community Photobucket: https://www.kawasakiforums.com/m_98590/tm.htm[*] Common Part Numbers : https://www.kawasakiforums.com/m_34306/tm.htm[*] DirtSurfer's Mod Day - One Stop Shopping for Mod How-To's with photos: https://www.kawasakiforums.com/m_100000/tm.htm[*] Mods and Other Information from the ADVRider thread : https://www.kawasakiforums.com/m_213768/tm.htm[*] Ride Report Index : https://www.kawasakiforums.com/m_233842/tm.htm[*] Put Yourself on the Map https://www.kawasakiforums.com/m_32803/tm.htm[*] Tips: How to Deal with Difficult Members : https://www.kawasakiforums.com/m_187406/tm.htm [/ul] Other good information


Q What's up with this little bitty tank? What kind of range can I expect?

A The stock tank is 1.9 gallons. This is good for all of about 90 miles before hitting reserve on an unmodified bike. Depending on your riding style you may do slightly better but don't count on it.

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Q Is there a larger tank available?

A Yes. Two in fact. IMS makes a 3.2 gallon tank for the older '94-'96 KLX250R and the current KLX300R. However, some modifications are required to install this tank on our bikes. It's not a huge deal but be prepared for 6 - 8 hours of effort to fit the IMS tank. Once installed, you can expect a range of 150 miles before reserve. Read more here.

There is also a tank available from Acerbis in Italy. As of April '06, I've not heard of anyone trying this option. If that changes, I'll update this answer.

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[align=center]Help! This bike is a slug![/align][font="verdana"]

Q What's the best bang for the buck performance mod?

A Most owners agree that the best single mod to get a bit more performance out of the KLX250S is to change the gearing. The stock gearing is 14/42 (14 tooth front sprocket, 42 tooth rear sprocket). An easy fix is to drop down one tooth on the front sprocket. There are a number of choices here but don't be fooled into ordering a sprocket for our sister bike the KLX300R. THEY'RE NOT THE SAME! The correct sprocket is actually AFAM part #24502 for a '88 EX 250 NINJA.

The stock 106 link chain will work for the 13/42 combo and this setup works really well. However, there are a couple of considerations: 1) the OEM sprocket includes rubber noise dampers on the sides to reduce chain noise. No aftermarket sprockets have this so you will hear a bit more noise if you change the front sprocket. 2) The smaller 13t will cause the chain to wear somewhat more quickly. So...

A number of riders have gone on to try larger rear sprockets too. Some even going back to the 14t on the front and putting a 45 on the back. This offers nearly the same final drive ratio as the 13/42 but requires a 108 or 109 link chain.

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Q OK, I've changed the gearing, now what?

A The KLX250S comes from the factory severely restricted to minimize noise and emissions. There's a great deal of performance potential in this little bike if you're willing to do a some tweaking. The following Q&As address this topic

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Q What's all this about re-jetting the carburetor?

A More to follow soon...

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Q How do I open up the airbox?

A OK, there are a few choices here. First let's discuss the "problems" with the stock exhaust and then see which way to go. The OEM muffler is very restricted to keep down the noise (a good thing, in general but a bit overdone) and it includes a catalytic converter (also good for the air but very heavy and a source of extreme heat). Also, the OEM header pipe is a bit too small for optimum flow (although this is not as bad a problem on our bikes as it is on the KLX300).

So, you can attack these issues in a couple of ways. Easiest thing to do is to take a longish 1/2" drill bit and bore a hole into the restrictor plate located just inside the muffler opening. This makes very little difference in sound but opens things up a bit.

Next easiest (and likely the most effective) is to just buy a completely new exhaust system (header, mid-pipe, and muffler) from Muzzy, White Brothers, Staintune, Big Gun, etc. There's experience here and elsewhere with all of these, especially the Muzzy (a very, very good system in all respects). Note that some of these may require the passenger peg on the right to be removed or modified (it won't open or close with some mid-pipes installed but can be installed in either position). Some folks just pop it off and put it in the tool pouch to be re-installed in the open position if a passenger is on board.

Another alternative is to buy components separately. The KLX300 benefits greatly from the killer head pipe sold by FourStrokeWorks.com mated to one of several different aftermarket mufflers (or the OEM KLX300 muffler which is more open). The degree to which the FSW header helps the KLX250S is somewhat TBD at this point b

 

Here's a pointer to the post on ADVrider.com that has links to TONS of information on the KLX250S

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