Turned out nice, u have great skills! Iv been starting to do the same as a hobby, but flipping the bikes for small profit. All Im mainly doing is removing everything from the bike and detailing them. I use plastic restore/polish on original plastics to make them shine. Then give it full maintenance with new fluids, record that so new owner see's it. People pay a lot more $ for a clean bike with maintenance records, plus I get to rip around on different bikes and learn about them.
This is an awesome video. very motivating. I just picked up a 2004 KLR 250 for $100!! Has 4000 miles on it and need complete overhaul, so this video again, is just what i needed!
Good job on the bike. I have an 88 model and love it. Cheap and not that outdated compared to the new 250’s. The pre epa models are said to have 28 hp. New bikes are only around 20.
Good video! Should have taken the bike out and got it muddy for us! I bought a 1982 Kl 250 in 1992 for $150. The bike had $2,300 mi on it.. and the carburetor was all gummed up and the bike didn't run. I rebuilt the carburetor and started driving it. It has about 5,000 miles on it now and I believe still the stock tires LOL. I don't know about the new ones but the old kawies are indestructible
I’m looking at a KLR250 and have been searching out videos for it. This is one of the best! I really want one. I hope it works out. The KLR650 is so common around here and very popular but to big and heavy for my use.
Awesome, gave me a few things to be looking forward to when I pull my 4 wheeler out and fix it. Only problem is I'm not a mechanic and never fix one before. Got it in it's current condition.
Man awesome video! I have first hand a KLR 250 1990 that looks exactly the same. It’s an amazing bike, never fails! I am in Chile and here it’s pretty hard to find replacement parts. Sometimes think this is the only KLR 250 in the while country haha. Though I have managed and kept the bike with the original look (no offense to your changes). Still loved your video and found it very inspiring. Will consider to copy some of your fixes. Thanks!
I have a 97 that I bought 2 years ago with 3500 miles on it. I've upgraded the exhaust on mine and re-jeted it. Upgraded the front fork springs, and seals. Rebuilt front brakes. The rear shock is pretty crappy. Not sure I want to spend that much but don't see a lot of choice. I still think it's a great bike. I turn off the petcock and let run till it dies. When I start it I open the choke and turn it over a few times and it usually starts first kick. The engine likes to rev but doesn't have a lot of torque. I'm probably going to drop 1 tooth on the front sprocket.
I tried to rehab a 1993 dr350s and all I ended up with was three pairs of ruin shoes from the kickstart. I was able to get it running good enough to sell it but God damn that thing just wouldn't run strong without sputtering and it started like a dog.
I’ve cut open plenty of air boxes before. I just can’t figure out why you would cut a little one inch hole and not just yank the entire snorkel. I didn’t want to deal with exhaust and rejeting so I just capped it.
Absolutely fabulous video! I bought a 97 klr250 last year to "improve". My friend removed the head light to get to some wiring and lost the mounting bolts which have a threaded cap to attach the cowl cover. I can not find replacements so, I may have to replace the plastic cowl like you did. What parts did you use to complete the headlight upgrade? Thanks for the info. These are really work horse bikes.
Thanks!!! The headlight I ordered off wish, look up dual sport headlights on Amazon, a lot will come up. I soldered a H5 connector to the headlight so I could plug it into the factory wiring.
@@DRIPPYRO_ I got it on wish, I couldn't find it when I just looked, but if you search amazon for dual-sport headlights lots of similar headlights home up.
I got a 99 KLR250 bought for $600, only needing a coil pack. But no title, vin is clean thi. is there a way to get a title in Tennessee? I'd love to ride it on the street.
Nice score! I’m actually working on a project car with the same scenario. I’m working with dirtlegal.com , they do title recovery services and have been great to work with.
The hole is to let more air in the box and the jets might have been changed to handle the extra air . You probably caused the bike to not run right by closing up the hole . Check the jet sizes and see if they are stock or not .
Hi. Really enjoyed your video on the 250. I just bought a 2001 klr 250 yesterday. Barn find. It looks rough. But everything is there except the side stand . The mount is broken off to install a new stand. Any ideas. Plus what was that engine brightener you used. Keep up the great videos 👍
i was searching for restoration videos of klrs stumbled on this one and i think if i copy you in the future i might fix my dads its not ecxactly broken he just stopped using it its in a garage for like 16 years now and im not sure cause i dont have the knowledge of what it will need to get it in working shape again its an 87 model if you have any ideas i would appreciate the help ty again
I thought you did a nice job on the seat, Check out seat concepts too. I just picked up a 2005, I think I got a good deal on it bit I can't get it to go over 40, throttle is maxed, even first gear seem like it's got no torque. Does yours 1st gear feel like its' got enough to pull you up a hill?
Yeah, I’ve been all over the place with it. Could be your gearing? It’s definitely not a highway bike but I’ve been on the highway with mine, it’s pretty rung out at that speed, but it’ll do it.
The rear box was just a cheap case from harbor freight. I keep my tools, ham radio, registration, and a few other odds and ends in it. I used the factory mounts on the bike and drilled two holes in the box.
I used Gunk Engine Protector Shine. It’s actually held up pretty well, and once you allowed to dry and wipe off any excess I haven’t had much of an issue with it attracting dirt or dust.
I just got a 84 kl600 for 350 bucks last week. It needs complete rewriting and among other things. For your rebuild carb kit did you use one from a klr650?
Blue fender was from one of my other bikes. At one point I was trying to see if it would fit. The black your seeing on the rear is my tool box, and on the underside the license plate mount and light housing.
By the way I’m looking to buy the front turning lights. You still have the original ones you took off? They looked in good condition. Let me know and I buy them.
Do you mean the number played with the headlight? If so, I don’t have the name, actually got enough wish. It lasted about six months off road and the light died. I’ve gone back to the original.
The biggest bummer of the whole video you gotta at least let us see you ride it for a second I don't have to be 20 minutes or anything but 20 or 30 seconds worth would have been nice 🤘
I had planned on including riding video, even went out and film some with my GoPro. The memory card went bad and I rushed to get the video out. You’re definitely right though, I should’ve had riding footage on there. Rest assured I’m still writing the thing all the time, finally blew the fork seals out a couple weeks ago riding out in the Mojave so they’re getting rebuilt again.
I also couldn’t track down and original front fender or light at the time. The light is now back to stock, but with an LED build, the stock bulbs were pretty anemic in the middle of the desert. I’m definitely an 80s nerd though…. You should see the car collection.
Use a klr 650 rear shock, you have to slightly widen the lower mount on the inside of it, you can rebuild the 650 klr rear shock
Turned out nice, u have great skills! Iv been starting to do the same as a hobby, but flipping the bikes for small profit. All Im mainly doing is removing everything from the bike and detailing them. I use plastic restore/polish on original plastics to make them shine. Then give it full maintenance with new fluids, record that so new owner see's it. People pay a lot more $ for a clean bike with maintenance records, plus I get to rip around on different bikes and learn about them.
I have a 1989 klr 250 that I rebuilt the motor with a wisco 300 mohive cylinder and piston, and bought a used head from a 1994 mohive 300 quad
Got yourself a great deal with that bike and you made it look awesome, thank you for the video.
I remember I had a green KLR 250 in 1992, I thought they were bullet proof back then. I never had any trouble with it.
Great bikes, this thing won’t quit!
This is an awesome video. very motivating. I just picked up a 2004 KLR 250 for $100!! Has 4000 miles on it and need complete overhaul, so this video again, is just what i needed!
Awesome! These are great bikes, have fun with the build! There are a couple great KLR250 groups on Facebook that have a ton of info on them.
DUDE! I just found a KLR 250 for $400. Needs new wiring, lights, and plenty of body pieces. Glad I found your video.
Sounds like you got a good deal! Shoot me any questions you have along the way!
I liked the old stock seat with the logo...but the new headlights, blinkers and new fender came out great! Cool 😎
Thanks! The vinyl on the stock seat was cracking, and getting worse every time I sat on it so it had to be replaced.
My seat no logo. Is it not original?
@@jamesconnor9142 OEM ones have "KLR" "250" or "Kawasaki" on the side
Good job on the bike. I have an 88 model and love it. Cheap and not that outdated compared to the new 250’s. The pre epa models are said to have 28 hp. New bikes are only around 20.
Thanks! These older bikes are tanks!
Good video! Should have taken the bike out and got it muddy for us!
I bought a 1982 Kl 250 in 1992 for $150. The bike had $2,300 mi on it.. and the carburetor was all gummed up and the bike didn't run. I rebuilt the carburetor and started driving it. It has about 5,000 miles on it now and I believe still the stock tires LOL.
I don't know about the new ones but the old kawies are indestructible
Looks fantastic. Great job. Love the baby klr
Thanks! Love this bike!
You continue to amaze me with the sheer breath of types of projects you tackle and do so well!
I’m looking at a KLR250 and have been searching out videos for it. This is one of the best! I really want one. I hope it works out. The KLR650 is so common around here and very popular but to big and heavy for my use.
These are great bikes! Good luck with your search!
Awesome, gave me a few things to be looking forward to when I pull my 4 wheeler out and fix it. Only problem is I'm not a mechanic and never fix one before. Got it in it's current condition.
These are great projects, pretty simple compared to pulling apart a car. There’s a lot of resources out there on the net too!
Great project, please bring old front end back!
It’s back on there now
Enjoying the video ,thanks for sharing. Only thing I would do differently is rebuild the forks and fit new fork covers .
Thanks! We did rebuild the forks and went with seal saver covers.
Man awesome video! I have first hand a KLR 250 1990 that looks exactly the same. It’s an amazing bike, never fails! I am in Chile and here it’s pretty hard to find replacement parts. Sometimes think this is the only KLR 250 in the while country haha. Though I have managed and kept the bike with the original look (no offense to your changes). Still loved your video and found it very inspiring. Will consider to copy some of your fixes. Thanks!
Thanks! Since the video I've gone back to the stock headlight and fairing.
I have a 97 that I bought 2 years ago with 3500 miles on it. I've upgraded the exhaust on mine and re-jeted it. Upgraded the front fork springs, and seals. Rebuilt front brakes. The rear shock is pretty crappy. Not sure I want to spend that much but don't see a lot of choice. I still think it's a great bike. I turn off the petcock and let run till it dies. When I start it I open the choke and turn it over a few times and it usually starts first kick. The engine likes to rev but doesn't have a lot of torque. I'm probably going to drop 1 tooth on the front sprocket.
Awsome! Take a look at teh KLR650 rear shock swap. That should save you a few $$
Good video bud keep them coming
I bought a 96 klr 250 for $1800 , the plastic looks new as well as the fuel tank , I rebuilt the carb. Nice bike , very dependable
Yup! Love this bike!
clean build.
I hope you still have the klr 250
I need more info on that box! Where can I get one like it?
Nice job Dad !
Thank you!
I tried to rehab a 1993 dr350s and all I ended up with was three pairs of ruin shoes from the kickstart. I was able to get it running good enough to sell it but God damn that thing just wouldn't run strong without sputtering and it started like a dog.
7:42 Bro not the speed hole! lol Probably somebody's way of getting more air. Some KLR guys just take the whole door off.
I’ve cut open plenty of air boxes before. I just can’t figure out why you would cut a little one inch hole and not just yank the entire snorkel. I didn’t want to deal with exhaust and rejeting so I just capped it.
Pretty cool
I do like the front fairing setup, how can I go about getting one?
I found that one on wish, the light wound up failing pretty quickly so I switched the light to another LED one off Amazon.
Hi. I have 1991 klr and I like it better stock but it was a good video. Maybe I'll put a box like your on the bike. Best regards.
Hey man!!
What type of weather proof lock box did you buy??? Did you have to drill your own holes to mount in the rear??
Should have done a white seat cover, that would have been really cool
Not great for dirt but great for SM.
Absolutely fabulous video! I bought a 97 klr250 last year to "improve". My friend removed the head light to get to some wiring and lost the mounting bolts which have a threaded cap to attach the cowl cover. I can not find replacements so, I may have to replace the plastic cowl like you did. What parts did you use to complete the headlight upgrade? Thanks for the info. These are really work horse bikes.
Thanks!!! The headlight I ordered off wish, look up dual sport headlights on Amazon, a lot will come up. I soldered a H5 connector to the headlight so I could plug it into the factory wiring.
@@DoItYourselfDad looking for the exact cowl , can u put a link ? That’d be great
@@DRIPPYRO_ I got it on wish, I couldn't find it when I just looked, but if you search amazon for dual-sport headlights lots of similar headlights home up.
Turned out nice, though I'm sorry to say I'm not a fan of mixing the new front fender & headlight shroud, with the old plastics/graphics.
I came to the same conclusion as well, I swapped the headlight back to stock.
I got a 99 KLR250 bought for $600, only needing a coil pack. But no title, vin is clean thi. is there a way to get a title in Tennessee? I'd love to ride it on the street.
Nice score! I’m actually working on a project car with the same scenario. I’m working with dirtlegal.com , they do title recovery services and have been great to work with.
Where can I get the white light plastic (I don't remember how it's called)
Where did you get the storage crate for the rear fender ?
It was from Harbor Freight.
The hole is to let more air in the box and the jets might have been changed to handle the extra air . You probably caused the bike to not run right by closing up the hole . Check the jet sizes and see if they are stock or not .
Jets were stock size, bike runs great right now. Maybe at some point the jets were changed and changed back? Who knows?
I do not see a link to the headlight you used. Do you still have it?
Hi. Really enjoyed your video on the 250. I just bought a 2001 klr 250 yesterday. Barn find. It looks rough. But everything is there except the side stand . The mount is broken off to install a new stand. Any ideas.
Plus what was that engine brightener you used. Keep up the great videos 👍
i was searching for restoration videos of klrs stumbled on this one and i think if i copy you in the future i might fix my dads its not ecxactly broken he just stopped using it its in a garage for like 16 years now and im not sure cause i dont have the knowledge of what it will need to get it in working shape again its an 87 model if you have any ideas i would appreciate the help ty again
Hi mate thanks for this I just got one from 1994. How did the cheap headlight turn out?
Not good… I switched back to that stock housing and upgraded the bulb to LED.
I thought you did a nice job on the seat, Check out seat concepts too. I just picked up a 2005, I think I got a good deal on it bit I can't get it to go over 40, throttle is maxed, even first gear seem like it's got no torque. Does yours 1st gear feel like its' got enough to pull you up a hill?
Yeah, I’ve been all over the place with it. Could be your gearing? It’s definitely not a highway bike but I’ve been on the highway with mine, it’s pretty rung out at that speed, but it’ll do it.
Next project: Ricochet skidplate. Well worth the money.
Definitely! I’m concerned about smacking that water pump!
Where did you got the white plastic on the front of the bike? At 6:15
I got it off Amazon (dont have the link anymore). Its a generic fender.
Awesome video! What is that rear box? Were there holes in the box lined up with the ones on the bike or did you have to drill?
The rear box was just a cheap case from harbor freight. I keep my tools, ham radio, registration, and a few other odds and ends in it. I used the factory mounts on the bike and drilled two holes in the box.
My battery went bad on mine but it runs ok ,will it make any difference with a new one?
I really haven't noticed a difference. I've seen people delete the battery completely and replace with a capacitor.
Great video, what engine brightener did you end up using? Have a KLR 250 that could use some love and yours looks great!
Thanks! Best of luck with your KLR!
@@DoItYourselfDad thank you! what engine brightener did you end up using?
I used Gunk Engine Protector Shine. It’s actually held up pretty well, and once you allowed to dry and wipe off any excess I haven’t had much of an issue with it attracting dirt or dust.
I just got a 84 kl600 for 350 bucks last week. It needs complete rewriting and among other things. For your rebuild carb kit did you use one from a klr650?
I lucked out and didn’t need new gaskets for the carb, so I just cleaned it and reinstalled.
awesome work...very entertaining. what rear fender did you use?
The rear fender is the stock KLR fender
@@DoItYourselfDad oh, from 5:02 in video, for about 5-10 sec, there’s a blue rear fender, and in the end, the white OEM is back. Just curious.
Blue fender was from one of my other bikes. At one point I was trying to see if it would fit. The black your seeing on the rear is my tool box, and on the underside the license plate mount and light housing.
Did you do a compression check before you bought it or just kicked it over and kind of see how it felt
I just kicked it over, when I went to look at it I asked the owner to leave it cold so I could cold start it.
That headlight isn’t just ugly. It’s hideous haha
It didn't last long, it's back to stock now.
Nice video! What trailer mechanism was that, that you hauled the bike on in the beginning of the video?
Thanks! It’s a hitch mounted motorcycle carrier.
Can you ride these on the beach on the hard sand? Or would that ruin it?
Thanks, nice bike too!
Yes you can, though you'll want to clean the sand and salt off as soon as you're done to avoid corossion.
@@DoItYourselfDad thanks heaps man.
I’m going to look at one w 2100 miles on it tomorrow for 1300 I think it’s a good deal. I? Looks in good shape but I will check it out closely
The two things to look for is cam wear and blown rear shock. The rear shock is not rebuildable and $$$ to replace.
Any chance to share where to buy that hard tool box?
I picked it up at Habor Freight. I’m not sure where your located but any discount took store or amazon should have something like it cheap.
Thanks man. I’m in Chile, South America. We don’t have that store in here. Will keep searching for one on the web 👍
By the way I’m looking to buy the front turning lights. You still have the original ones you took off? They looked in good condition. Let me know and I buy them.
Can you tell me the name of the mask
Do you mean the number played with the headlight? If so, I don’t have the name, actually got enough wish. It lasted about six months off road and the light died. I’ve gone back to the original.
My KLR seat does not have KAWASAKI on side. Not original?
All of the original ones I’ve seen have either said Kawasaki or klr250 on them.
If you rub the side of the seat with carb cleaner the letters will disappear
@@DoItYourselfDad
Disappointed not original
The music is a little loud. but in Love the video Good job
The biggest bummer of the whole video you gotta at least let us see you ride it for a second I don't have to be 20 minutes or anything but 20 or 30 seconds worth would have been nice 🤘
I had planned on including riding video, even went out and film some with my GoPro. The memory card went bad and I rushed to get the video out. You’re definitely right though, I should’ve had riding footage on there. Rest assured I’m still writing the thing all the time, finally blew the fork seals out a couple weeks ago riding out in the Mojave so they’re getting rebuilt again.
I don't know about the front gard looks poxie
I need a cdi to my 91 klr 250 anyone know where I can buit??
nice bike awful front headlight and
I agree, already went back to stock, just switched to an LED bulb for more light.
You devalued that bike with in my opinion that ugly cowling and fender
Four bolts and you can slap the old stuff on, nothing permanently changed, nothing devalued…. Plus, I bought it to ride it, not as an investment.
@@DoItYourselfDad sorry I'm just an origialist when to the older bikes .I don't like the modern look on them
I also couldn’t track down and original front fender or light at the time. The light is now back to stock, but with an LED build, the stock bulbs were pretty anemic in the middle of the desert. I’m definitely an 80s nerd though…. You should see the car collection.
Sorry but that front fender looks horrible