Hey guys ... hoping someone can shed some light for me
I recently had a little engine problem which has brought me to rebuild the motor, so I bought a 300cc big bore kit direct from Kawasaki. Only problem is, when I try and put the barrel onto the motor, the protrusion does not fit in the hole. I have tried using a rubber mallet to tap it in, but to no success.
The only thing I can think of that may be the cause of this problem is that it is a '93 klx250 and the kit states it is for the '03 model? Didn't really think that there would be much of a difference.

 

I thought 1994 was the first year of the KLX250/300 generation. Anyways, the 300 barrel will not fit the 94-96 KLX250 cases. Some machining of the cases or barrel has to be done. Contact Jerry at Four Stroke Works. He can make it work for you. He put in a 331 using a 300 barrel on a friends 1996 KLX250.

 

The build date of the bike is '93 ... not sure if it is classified as a '94 though.
So the barrel won't fit the '94 unless machined ... hmm ... time for some modification then I guess. Sucks not being able to do the engine until almost the last stage of an entire bike restoration/modification. Especially since every shop is closed for Christmas (curse you Santa!)

 

Bill Blue might be able to help you?

b_jblue@sbcglobal.net

 

The O.D. of the stock 300 kit is larger than the O.D. of the early model cylinder. I have installed 300 kits in the early model cylinders. I can put your cylinder in my lathe & turn the O.D. of your new cylinder to the same size as your stock cylinder.
Bill b_jblue@sbcglobal.net

 

Damn....can't beat that.

 

Bill to the rescue!!

 

Very COOL!!!

 

This site and it's members love for the bike is great!!!!
Glad I bought one and joined!!

 

Thanks for the offer Bill, but I think it would be easier if I took it to work and put it on the lathe there ... I have access to a full machine shop (lucky me).