I've been toying with the idea of upgrading my 250 to a 300 for quite some time now. This is an old review from ADB Australia regarding the upgrade kit, but it's made up my mind. Hope its useful.

http://www.fracknaps.com/read/?p=T37PZPXY

 

Go with a Kustom Kraft 331cc upgrade. The price is similar and you might as well go all the way if you are going to tear down the motor.

 

Kawasaki assembles the KLX locally, so the only kit available directly is original parts. If I go for a third party kit, I'll need to import it which will be time consuming and really expensive. I'll be importing the Clarke tank, but thats because I have no local alternative.

 

I can install a sleeve in a extra cylinder I came up with & do a exchange with you by charging you a core charge. Then return your core charge to you when you send me your cylinder. A 300 kit cost $335.00 or a 330 kit cost $455.00
You can contact me at b_jblue@sbcglobal.net
Bill

 

Thanks for the offer, but after I factor in shipping and import duties, and clearing paperwork with customs it's going to end up being very time consuming and costly.

I can get the original Kawa parts fitted and installed for less than $US500 all in. Plus it's direct from the local Kawa factory, and fitted by their main dealer who will maintain the warranty.

If I didn't live in South East Asia, I'd be happy rooting around with all sorts of stuff, as it is I'm limited to what I can access locally. Importation is expensive and VERY time consuming.

 

You will be impressed by the power increase to 300cc. I'm running 300cc with wiseco piston and aftermarket cams right now...love that added torque and acceleration.

I hear you on import hassles in SE Asia. I've heard of themputting up to a 200% tariff on certain items, so I can only imagine how bad other aspects must be.

 

Has anyone here done Bill Blues upgrade? (300 or 330)
What else needs doing along with the cylinder?

 

Who has used the stock carb for either the 300 or 330 and what did you end up with for jetting ? Seems I've heard most who go to the 330 go to a pumper carb. If that is true, that is an extra cost that must be considered.

 

I put Bill's 331 upgrade on a few months ago (thanks Bill, it's awesome) and run the stock CVK. My bike runs with no airbox lid, stock header and FMF Powercore 4 muffler. I upgraded the carb to use the N1TC needle a while back, so now it's got (from memory) a 40 pilot, 132 main, air screw 2 turns out, needle on the 2nd clip. It's a little lean from just off idle up to half throttle so I suspect I need to go down another clip position or two. If I can sort out the slight lean condition I'd say a pumper is not necessary, the throttle response is like stock except 'stronger', it still has that elastic response that a CVK gives. Good enough to run in 3rd and 4th and do powerslides around corners on dusty semi-open firetrails.

Bill's kit is complete, barrel, piston, rings, circlips and gaskets. Pull the tank and plastics off, carb off, head off, barrel off, piston off, then assembly is the reversal of the disassembly process as Kawasaki like to say. Not hard, not too fiddly, just get the torque settings right and make sure the valve timing is correct. There's a great pictorial here somewhere from Nobrakes that makes it very clear (thanks Nobrakes, always good to see what's in there before doing it myself ).

Also Bill is very helpful with advice, he's great to deal with.

 

Yeah Bill's is the complete kit.

Just a recommendation though....remove the radiator. That's actually the official procedure used by Kawi. I've read about more than a few people poking a hole in their radiatior while changing the jug just because they didn't want to spend a few extra minutes changing the rad and anti-freeze...not worth the risk in mybook.