sry if this has been posted before. My shop manual just showed up this morning and the part numbers match but on the back it only goes up to 1996 KLX250. Some of the specs match but most dont. I ordered this through bike bandit and im just wondering if this is what ever body eles has??

 

If you have 99924-1165-03, with supplement 99924-1240-55, you have the right manuals. The main manual only goes to 1996. The supplement goes to 2005. The supplement shows that the -H6 model is a 2004. All of the paperwork that came with my 2006 KLX250S indicates that my bike is a -H6 model. I've used the manuals for suspension information, and for removing the piston and cylinder to install the 300cc setup. What I needed to know was in the book, you should be just fine.

 

Can you tell me about removing & reinstalling the cam chain tensioner? I have big bore parts on the big brown truck& no manual when they get here. I can handle gettign the cams linied up & all that--just the tensioner part.

Thanks

 

Remove the center bolt (the big one) first, be careful not to lose the spring, washer, or o-ring. Remove the two mounting bolts last. After you have the assembly out, unlock the ratchet stopper and push the rod into the tensioner body. Installation is reverse order of removal (the large bolt with the spring goes in last). The small bolts are torqued to 9.8N-m (87 inch lbs), and the large bolt is torqued to 15N-m (11 foot lbs).

You really should have a manual if you are changing out the cylinder and piston. It has instructions and torque specs for the head and cam bolts, and it also points out where the coolant drain plug is (I had intended to just pull a hose until I saw there was a drain).

 

Thanks, I have the torque specs from some kind members here. So torquing the large bolt at the end correctly tensions the chain?

 

Yes, the cam chain tension is self adjusting. There is a "slide guide" inside that the chain rides on. The spring pushes the rod into the guide. The rod is a ratcheting device, and once it extends it can't retract. When you install the chain, start with the exhaust side.

Quote from the manual..."Pull the tension side (exhaust side) of the chain taut to install the chain. The timing marks on the exhaust sprocket must be aligned with the cylinder head upper surface and pointed toward the front. Pull the chain taut and fit it onto the camshaft sprocket. Starting with the timing mark on the front of the exhaust sprocket, count to the 32nd pin. Feed the exhaust camshaft through the chain and align the 32nd pin with the timing mark on the inlet camshaft sprocket."

Basically, make sure the chain is tight from the crank sprocket to the exhaust camshaft, and the timing mark lines up (no slack). Then, after you align the chain over the inlet sprocket, there will be 32 chain pins from timing mark to timing mark. All of the chain slack will be below the intake camshaft, and will be taken up by the self adjusting cam chain tensioner.

 

Very much appreciated, exactly what I was looking for.