It was raining today so I decided to proceed with a most unneccesary modification; relocation of coolent overflow vessel. I had purchased a supermoto style catch can for my XR650r but never installed it. Since my interest in that bike is waning I decided to give it a try on my KLX250s. Here is what the product looks like;

[IMG]local://upfiles/8769/3F18BD7BA5A34E788E965E21A41B651B.jpg[/IMG]

 

installation is straightforward enough, just find a suitable location for the new catch can. I used the left side of the motor behind the shroud. It fit nicely within an existing hose and a few zip ties hold it in place. I added some heat reflecting tape on the side that faces the motor. Take a look;

[IMG]local://upfiles/8769/C24CE370C2FF4B2FBD6BB6A2A4E023C6.jpg[/IMG]

 

There is a sight tube which allows you to keep an eye on coolent levels. I added about 35cc of coolent to the can and hooked up the overflow hose to the radiator and the vent hose was routed up and over the frame. Removed the old coolent vessel by the rear and pulled out the 3 feet of hose routed to it. No performance gain, no weight saving and no real reason to do it. Like I said; it was raining today..........

[IMG]local://upfiles/8769/8D0618264ED44D919CED17DB1F687241.jpg[/IMG]

 

Now if you could relocate the battery, you might be able to use KLX300 side number plates. The right side KLX300 fits, but the left side does not due to the battery and catch can. With the KLX300, you have non-OEM plastics options and different colors, etc. Finding another place for the battery would be tough though. Maybe under the seat in airbox?

 

Now there's an idea. I did a similar thing on my Xr560r. Since the bike is 100%street I could go to a K&N clamp on type air filter right off the carb and then remove the airbox altogether. Battery could no doubt fit in the void created by that. Hmm....perhaps on another rainy day......

 

I'm running a clamp-on BMC(same design as K&N)filter right now. You could remove the front part of the airbox and fashion some sort of blank-off plate...or, like you said maybe remove the airbox all together. The only other issue would be where to run the cc breather hose, but there are plenty of options for that.

Iremoved the front half of the airbox and replaced it with an aftermarket oil catch tank that bolts right in place. That gave me enoughroom to install the filterandI'm using the void in the airbox to store my tools [8D].