Posted by William on 8/11/2003, 6:15 pm, in reply to "KLR 250 Mod TIPS"
66.19.76.51
I have a 98 KLR 250 and it is hard to find stuff. I don't think there's much you can do with the stock parts. I added a Cobra exhaust; it's DOT & USFS approved. I added a TwinAir filter (K&N doesn't make one for it anymore). You can also get UNI filter plugs. A set of 6 plugs will cost about $10. You should be able to find room to drill 4 - 1 inch holes in the air box BEFORE the air filter and install the filter plugs in the holes for more flow. Notice I said BEFORE the air filter. Even though these filter plugs have a small foam element, if you install them AFTER the filter, they can let enough dirt in to damage your cylinder bore. I found out the HARD way. If you do this and rejet it, you will notice a difference. With no wind to speed me up or slow me down, mine will usually top out at 85 mph at 8500 rpm, with about 1000 rpm to spare. I found a 1 tooth smaller front sprocket (couldn't find a bigger rear), and now it does 85 at about 9000 rpm - no loss of top speed and a slight gain in acceration. I found information about a cam from a company called Megacycle. I haven't looked into buying one yet. NOTE: with the mods I did, it will continue to make power above the 9500 rpm redline. HOWEVER, if you let it go above redline far enough and often enough, you can wear down the cam and rocker arms. I found out about that the hard way too. I also found out about an IMS plastic tank that increases fuel capacity from 2.9 to 3.2 gallons -not much increase, but it should be lighter, and lower the center of gravity because you're reducing weight up high. I ordered a Works shock and spring through Pro Action and had them re- work the forks. The suspension is much improved, but it still is no motorcross bike. I ride mine in the Ocala National Forest here in Florida, and due to the sand I bought Dunlop D606 tires. They look just like normal dirt bike tires, but are DOT approved and should last longer than the factory tires. After I wore them out, I installed Pirelli MT21 tires. They do about as well off road, but wear quicker. Get the Dunlops. There will be a small amount of noise and vibration increase, mostly at low speed, but the Cobra exhaust and engine vibration masks the tires at high speed. By the way: one time I was on Interstate 4 going down a slight hill and with a good tailwind, and with full throttle was showing 100mph on the speedometer!
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