For months I've been trying to find the electrical issue I thought I had with no luck. After braking down again mid ride today I got it to a mechanic who tested the electrics unable to find an issue. In the end he diagnosed the tourqe limiter as faulty/slipping which has been causing the problem usually mid way through a ride.

He welded it together, so it can no longer limit the torque I guess, but after installing and testing, the bike now starts without issue.

So two questions:

1 - why has this part failed? I couldn't really find alot of information in regards to the klx250 of it failing. I have the 330 kit installed if that has something to do with it. Or is something else going on deeper in my engine?

2 - should I replace it immediately now that is back home with a replacement unit? I did find info of people welding them on certain bikes, ktm, hyabusaa, klx 450 to name a few, but weather is advisable or not... I do not know. Hopefully someone here does.
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Keng Engine also makes a replacement torque limiter that takes care of this issue. I installed one on my klx 402 engine build due to it having no KACR and the much larger piston. He has a YouTube video talking about it. It's all in Thai, but has the CC to translate it.

 

Awesome. I'm friends with him on facebook and just got a throttle housing off him last week. I've just shot him a message. Thanks

 

Mr Keng delivers the goods