Just finished my winter project on my 09' thought I'd share a couple of pics with you folks.

I added: Pro Taper Atv Hi bars, Moose racing hand guards, Symtec Atv grip heaters (with a home brewed aluminum mount for the switch), Progrip 714 gel grips, Motionpro +2 in clutch and throttle cables, Russell universal steel braided brake line, and my Garmin Zumo 550 with RAM mount.

Did my 1st real ride on it on Fri and am supper happy with the new riding position. I also added DRC wide foot pegs and a Moose Racing XR 650L shifter. Spent way more $ then planned but it seems like all projects like this end up that way. All I wanted was higher bars!

Next up is a relayed fuse block to power the grips and gps. Currently they are going right to the battery. I can not find a good spot to locate it though. It's real tight under the seat. Any of you guys mount up a fuse block anywhere?

 

Is that the stock brake line? I tried installing 1" bar risers today and there wasn't enough slack in the brake line (or clutch & throttle cables for that matter) when I turned the bars from one side or the other. Even with the stock bars I don't have as much brake line slack as shown in your picture.

 

Got to read,, don't just look at the pictures!!!

 

All cables and brake line were to short and had to be replaced with custom one's. Do be honest I felt the stock brake line with the stock bars was to short to begin with.

 

Doh!

I'll have to order new cables and brake line. I installed hand guards yesterday and the stock cables & brake line are barely adequate once routed around the guards. I'd really like to add bar risers too. The only other issue might be enough slack in the wiring to the switch gear, but I haven't traced the harness to see if there's some slack somewhere.

 

You don't happen to have part numbers for the longer cables? I checked the Motion Pro website and they list replacement cables for the KLX250S, but don't give a length or any information to help in ordering longer ones.

 

I just ordered a 2" longer cable, they use the stock part# with a +2".
You have to call and order the custom cables over the phone.
The clutch cable to PA was $40 plus $8.95 s/h.
I did shorten the bars by 2", 1" of each end. Didn't need the throttle cables.
The HI atv bars do fit nice sitting and standing.

 

I did the same just gave them a call ordered over the phone and the cables were in in about a week.

I ended up ordering:

Cable, Black Vinyl, Clutch: Part # 03-0389 + 2 in
Cable, Black Vinyl, Throttle Pull Part # 03-0387 + 2 in
Cable, Black Vinyl, Throttle Push Part # 03-0388 + 2 in

With the bars and hand guards in the position I wanted them at, when I turned my bars left to full lock the throttle would not move no matter how I rerouted the stock throttle cables. All the +2 cables fit great and are made great. Motionpro was pretty painless to deal with.