Good day all

So I've recently acquired a non-running KLX250R that dropped valves. PO didn't have the head anymore, so after some time I managed to get a KLX300R head that is still in decent nick.
I've since discovered that the 250 cylinder will need to be replaced, and without importing a new cylinder which is very expensive to get to South Africa, it will be more viable to have the cylinder re-sleeved.

Now I have two options
1. Re-sleeve to the standard 250 bore OR
2. Re-sleeve to the OEM 300 bore

What I cannot clearly deduct is, are the 300 and 250 piston pin the same?
When searching in the parts diagrams it seems that the connecting rod can be used for both the 250/300, so it should be the same, right?

Any help would be greatly appreciated!
Cheers

 

The difference between the klx 250 and 300 is bore diameter. The stroke is the same. You may as well go to 300cc if you have to re-sleeve the cylinder.

Ride on
Brewster

 

Thanks @Brewster , seems that is the plan that I'll be going for. Will be porting the head while I wait for the parts to be imported.

 

Putting in a china 300 kit in my 2012 klx250s right now. The pin in the 300 kit is wider. But not sure about the OEM.

A side note is the 300 complete kit is 23.8 grams heavier 258 vs 234. But the pin is actually .5 lighter. But it's wider.

 

Thank you @ctbale . Though about using the China kit, but it's cheaper to import the OEM stuff to SA, so going to stay OEM.
As long as the piston pin is the same diameter, it's good.
I'm sure the weight shouldn't be an issue for the internals?

 

TNC, a member, has been running a Kaw parts 300 kit for probably over ten years now. It's a bolt on without issue.

 

Thanks @klx678 good to hear.

 

yea, thats good to here. I have actually been sitting here for two days trying to decide which one to install. I have the 300 china kit that is very popular, but my original oem piston and cylinder is perfect, bike only has 5000 miles. and I have a brand new oem piston I could just put in there and I am back to stock. I had my jetting spot on with the dyna jet kit with the 249cc set up. trying to decide, trying to decide.....haha

 

For the price the AHL 299cc kit is hard to turn down. I doubt you could do the cylinder bore and liner or plating for the cost of the AHL.

 

So, the re-sleeving of the cylinder plus the OEM parts have worked out too expensive, which has led me to rather purchase the AHL kit.
Anything in particular that should be looked out for when installing the AHL kit?