The 2009 klx250s front brake rotor pattern is a match for the klx650 hubs. However the bolts threads on the hub are too small. The 2009 KLX250s bolts are larger 8x15 and the KLX650 bolts are 6x14.

I'm not sure if I should even use the smaller bolts because the rotor has the recessed little hole before the actual hole. Do you think if I just switched the rotor backwards so the recessed hole is on on the inside I could use the smaller bolts?

I'm not sure which way would be safer or if putting the rotor on the hub backwards would even match up with the brake calipers. I'm hoping they have 6x14 bolts at the local hardware store so I can give it a shot. I do have a KLX300 rotor coming in the mail but that was meant for the OEM 2009 dirt wheels...

We shall see....

 

Here is the issue...a picture is worth 1000 words. I am pretty bad explaining things but I think this will show the snag I've run into. That is the 2009 klx250s front rotor on a KLX650 hub.

Forgive my nasty thumb, a dog bit it. Then he bit it again a month later.

I just saw that the KLX300 bolts and the KLX650 bolts are the same exact size, 6x14.

 

Yes the 650R dirt version has the small bolts. However, the 650C dual sport version (like the red one in the pic above sjould have the larger 8mm bolts & bolt right on. The problem with that is it is a larger disc so you would need to make a caliper relocation bracket & I dont think any aftermerket ones are for the stock 650C size.

 

I'm so confused now. I'm starting to think that the KLX300 rotor I have coming in the mail will now fit this klx650 hub. I'm not sure which "red one" you are referring to but the threads for this hub are definitely smaller than 8mm. The model I selected to get 6x14 is the R version, 1996.

6X14 matches KLX300 and KLX650r thread sizes, at least for the model klx650 I selected.

EDIT: In the meantime, I am going to attach the rear rotors to the motard wheel. The 09 klx250 rotors are the same size, 320mm, and the nuts are the same size. So it turns out I didn't need to order the extra Titax rear hub since DDT included one. The Titax one is really ugly, I wonder if I should just leave it in its package and sell it or whatever. Do rotors ever go bad? I mean besides getting scratched or bent. I don't want to screw up my brake pads with a crappy $10 rotor.

 

The 2009 klx250s rear rotor and oem 42t sprocket fit the klx650 hub no problem.
Now to go fit on the actual bike itself...

I THINK I can use the KLX300 front rotor coming in the mail for the front KLX650 hub. I was going to use it on the dirt wheels, but I don't think it's going to be possible. The KLX300 and KLX650r front rotor bolts are exactly the same size. Only issue I see is the rotor not reach hi enough up to the calipers.

Sorry for the thinking out loud, but maybe it'll help someone out eventually.

Got the rear wheel on. Looks pretty good. I know all you guys love the green, but I must say the red black and white is pretty mean looking!1

 

Yes, the 300R rotor will go right on a 650R hub (but not a 650C).

 

Im kind of confused here, when you keep refering to the klx 650, do you mean c or r. I have a klx650 c and have been looking to sm it for a while. does this mean the klx250 hubs fit front and rear?

 

I mean C.

I can't remember if I had C or R hubs. Pretty sure I had R, because in order to get the speedo to fit I had to yank the rubber seal on the 250 speedo to get it to fit/work. But my point was that if 650 hubs fit the D-Tracker, and an 09 250s, then logically a D tracker, or 09 250s hubs should fit the 650.

Am I wrong in thinking that?

If anyone in the central TX area, Austin specifically, wants to meet up and swap wheels to see how they fit up, I'm game. I do know that my rear rotor fell a little short height-wise in the caliper and that the pads didn't fully match up from 250s onto the 650 hub/rotor and rose a little above the rotor. Not a huge deal but would eventually cause uneven rotor wear, with a little breaking power lost. Not a big deal if you don't plan on switching that wheel out.

All I know is that my 09 250s converted was a BLAST and I really regret selling those 17" 650 hubs/wheels since I now own a 650c.