So I brought myself a treat a 2009 klx250s has 64,061km on it work horse of a bike just recently have had to replace the inner clutch case (cracked) along with a new radiator aswell (bent/broken) the bike was unfortunately crashed on a track the rider was rushed to hospital but unfortunately he did pass away.
anways just want to know what sort of problems might be coming my way soon


The crack was only small but a big pain in the bum

 

Check the valve clearance, replace the spark plug with the correct NGK, change the oil frequently (some people here will disagree with me, but the 7,500 oil change interval per the manual is ridiculous) and let it rip. These are very basic bikes with low-performance/un-stressed engines. There's not much to worry about.

At that mileage I would remove and clean the throttlebody, lube the cables, change the brake fluid, change the fork fluid, replace the fuel filter and check the condition of the air filter.

 

About the only thing that seems to come up over time is if the cam chain tensioner starts to fail. If it does there will be a rattling noise around 4000-6000 rpm. Gets worse over time. There is a chance the bike already may have a manual tensioner I make. Here's a picture of one so you can tell.


If the bike already has one here is a link to the installation, which has the adjustment techniques toward the end, should you need it. Click here

Carb tuning may be done on the bike. Here is D. Pippin's KLX250 web site, which is a gold mine of information, if you have the carb apart to clean it you can compare jetting. click here I hope this helps some. Don't be afraid to ask questions and you can use the search here for information. I happen to have a 2009 KLX250 as well. I am finishing the process of installing an AHL 299cc kit and a Mikuni TM36-68 carb on it. I did the stock carb mods, the MCM cam timing change, and the snorkel swap, picking up some more power. It was fine, but for under $200 a big bore was too attractive to pass up and the Mikuni pumper carb is supposed to really quicken the response of the engine... so I figured why not.