Hi All.

I've just bought a 2009 KLX250. It's a great bike but needs a lot of fixing up. I've found all the parts I need except the front brake disc.

The bike is an import not available where I live so some parts can be hard to find. I've checked the usual websites that will deliver to my country but drawn a blank for the front disc. The old one is wafer thin so I guess the previous owner also had problems finding a replacement.

I guess the same disc was probably used on many other bikes. Have any other KLX250 owners had similar issues and found which other bikes share the same front disc as a 2009 KLX250? If I knew which other bikes use that disc I could widen my search and have a much better chance of finding the part.

Thanks in advance

 

EBC makes discs for the 2009 klx 250

 

Thanks. It's finding a supplier that will ship to my country that's difficult. The postal system is very hit and miss so most western suppliers won't risk sending as they risk losing money if the item isn't delivered properly. Aliexpress or Chinese suppliers on eBay are usually the best option as many of them ship worldwide (although the parts themselves may not be the same quality as the Kawasaki originals).

I've searched and found dozens of Kawasaki front discs and KLX front discs but not for the 2009 model. I'm sure Kawasaki didn't fit that disc exclusively to the 2009 KLX250 and many of the discs advertised for older KLX250s or other models around that time probably fit. I just need to find out which are interchangeable.

From what I can find from some internet investigation I think the 98-06 KLX250 disc might well fit but is possibly slightly thinner (link attached). Can anyone confirm or otherwise this one https://www.aliexpress.com/item/Moto...6-0ba5d343830d will fit a 2009? Even if it is thinner, it is still within the 2.8mm service limit and would be a big improvement on the razor thin disc that was on the bike when I bought it.

 

P.S. The EBC tip was really helpful. Even if I can't get an EBC supplier that can deliver to me, EBC list the specs of the disc so I can trawl the internet for suppliers that can deliver who have something with the same dimensions.

 

Any KLX250S, KLX300R or KLX650R rotor will work. I have one on the front of my 09, is around .115 thickness and doing fine. There are also some KX models that should fit, possibly the KDX200 and 220 will work, since they used the same hub machining on the rotor side. Only difference in hubs between all of them is the machining on the speedo side, it is for electronic drive on the 09 and up, for a mechanical speedo on others, but the MX which has no speedo drive machining..

You can find them on ebay for $20. Fact is here is one for a bit under $20 that would ship to me for free.

What country are you in? I sell cam chain tensioners sending to most any country. Only ones I've had problems with has been Namibia and Kazakhstan. We could set up a relay, you find one and buy it, have it shipped to me, and I ship it to you if that's necessary. Let me know if I can help. I've done this before for some other riders. No charge, just the shipping cost to you, which can be verified on the USPS web site.

 

KLX678. Thank you very much for that info. If theKLX250 98-06 disc fits, that should solve my problem. Plenty of suppliers on Ebay/Aliexpress have that model available for delivery to Cambodia but not the 09 onwards version for some reason. It seems the 09 is 3.5mm and the older one 3mm but if the hub mounting is the same that will be fine. Also the 09 has a rubber damper beside the front disc which may get in the way of the protruding outer ring of holes on the 06 disc but I don't see that being a major issue. I posted a more detailed reply last night with some schematics of the 09 front brake vs the older version but the post has not (yet) been approved by the admins.

Also, thank you very much for the kind offer to relay a disc from the US. I really appreciate it but wouldn't want to inconvenience you. If the 06 disc is suitable I will be able to get one of those delivered direct.

Thanks again. The info you posted was exactly what I was looking for.

(More detailed reply possibly to follow depending on admin approval. Next time I'll copy my reply before clicking post in case the admins block it due to attached pics/schematics.)

 

I checked the existing disc with my vernier calipers this morning around 1mm. Slightly thinner in parts. I'm not even sure how it can be this thin on a bike that's done 28000 miles. Would this happen if it had been ridden with totally worn out pads?

If the cause is likely to be something else I'd like to work it out so I don't ruin the new disc.

 

Mine is definitely pre-09. .115" is about 3mm thick here is a picture that shows the rotor behind my fork leg that shows my speedo wire routing to pull the wire in away from getting ripped off.

 

Thanks for the info. I've ordered a KLX250 98-06 disc from an ebay seller in China. Seems to be 3mm rather than the OEM 3.5mm but that should be fine and I can change pads earlier if necessary to compensate. The hub fittings seem to match up as you said so, other than being 0.5mm thinner, the only other difference seems to be that my current 09 disc is solid while the 06 I've ordered is floating like the one you've fitted.

 

It was on the bike when I got it. Apparently a previous owner had a second set of wheels and the petal cut rotors went with them. The rider I got the bike from had the 300 rotor on the front. He also had an aftermarket rear rotor that was too small. The 09 and up have a larger rear rotor, 240mm, I think. The pre-09 have a 220mm, again I think, The difference was the carrier. I cut a deal with another rider here, where I got his smaller carrier and he got my larger carrier, because I wanted the smaller rotor. A bit less brake power for trails and trail braking on the road, a bit less likely to lock it up. Either way, the point is with the pre-09 caliper carrier you can run the common 220mm KLX250/300 rear rotor. I don't know how common the bigger rotors are. I do know you can get cheap used rear rotors and possibly the carrier for low buck too.

Now you know more than you wanted about KLX brakes.