Restorations and modifications I've done on my 1990 KLR250D :
Thermo-Bob 2 for KLR250
Stabilize engine temperature swings and eliminates cylinder hotspots. It is originally a popular mod for KLR650 brother
Kawasaki cut corners in the KLR cooling system, and the Thermo-Bob modifies KLR's cooling system to operate like automotive systems have for decades. In stock form, the KLR runs too cool in colder climate.
Ebay Aluminum Skid Plate for a Kawasaki KLR250 1985-2005
Mojave intake camshaft 12044-1181
As my original intake cam (would have been part number 12044-1119) was worn I replaced it with easily available Mojave cam. It looks to have more aggresive and higher profile. Works very well.
An important note when changing camshart is to
- Change the follower at the same time
- Use specialised cam assembly lube liberally (not just oil)
- Running in process of fluctuating around 3000RPM for 30 minutes to seat the cam and follower
I did not do those and was worn again soon
Immix Racing cargo carrier
From Amazon:
Barrett products pannier hoops
I bought these plain hoops and mount it easily using steel plates
Mounting it: https://www.youtube.com/watch?v=OtP2BAbPFj0
Ebay 5L motorcycle jerry can
Very robust and strong mounting. I've crashed on to it with no problems
Ebay Heater Grip
"7/8 inch 22mm Motorcycle Universal Heated Molded Handlebar Hand Grips Warmer"
It's got 4 temperature settings which can be operated using left hand. I connect it using a relay patched to the day running light cable
T-Mod
To prevent carburettor to starve from fuel when doing water crossing, add a plastic T-connector on the breather hose
Ebay Generic X-Grip motorcycle mount
Very strong and has already got a USB charger to make a neat installation
Ebay Cigarette-lighter and USB charger
Cigarette lighter socket to power up tyre pump etc and 2 USB charger.
Some versions have voltage indicator also. I wired it directly to the battery as it's got a switch. Useful when the motorbike is not running
Oxford OL200 Topbox 24ltr
From Ebay: https://www.ebay.com.au/itm/153508124910
Tubeless tyre mod
Using generic tube to convert the spoked rim to Tubeless tyre
Front gear 13T
The stock 15T is great for all-round road and dirt. I've tried 16T and it's great if you do 110kph+ trips
13T is great for dirt and climbs enduro tracks
Supercheap ToolPRO 300mm
Great to organise toolbox, tyre lever etc. and can move between bikes quickly
Tyres
My main criteria is 50/50 handling and ease of installation, in case I need to fix punctures on the road. The compromise of softer compound is tyre life
Rear: Dunlop D605 4.6-17
Front: Continental TKC80
KTI Personal Locator Beacon (PLB)
Emergency locator, hope I never have to use it but necessary when heading into remote areas
KLR250 Service Manual
I always carry a .pdf copy of the service manual on my phone... just in case. You need the base manual as well which is actually a KLR600 one.
Download link:
Others
Archive of old KLR reference page:
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