New member with a not so new KLR 250 (KLR Project)

[dixiedevil]

excellent build thread!

[BakonMoto]

 , dixiedevil! 

Bryan

[crpt]

Some might find this information useful. We all know that sometimes is more difficult to find the right material/component than buying the OEM ones. But the last are usually quite expensive and most times it's not even the best choice. Only the easy one.
So here goes some more reference number in this case for valves from the Japanese maker VESRAH.
Exausth  -  GG-4018-EX  24.70x5.50x87.16mm
Intake    -  GG-4018-IN  29.00x5.50x89.09mm

Haven't checked yet, but they also carry this ROD kit, which includes the rod+pin+bearing:
Rod   -   VA-4008 They mention this for the Kawasaki KEF300, KLF300, KVF300. Respectively Lakota, Bayou, Prairie

[crpt]

Lighter PISTON
Last time I wrote about it there were few photos and explanations. If you guys have been following this thread, probably remember. The old OEM piston blew up. That had nothing to do with the cutting to make it lighter. I simply went completely overboard and made this engine behave like a good 450     Didn't last long but it was amazing to say the least.
Anyway, good things to maintain that really work.
- Lighter piston - Revs much faster, also with less vibration.
Bad things to avoid in the near future:
- Much lower compression ratio.  
With that in mind. I took that new "Namura" piston that can be seen some pages back. And started working on it. For all purposes it's "new" with something like 500km on it's skirt. Quite frankly don't remember how much exactly.
Talking about skirt that's where most of the weight will come off. The ideal scenario would be to work it with metal lathe and mill. But since most times it's hard for me to get my hands on any of those. I went for the old school approach, that meaning angle grinder, electric drill, sand paper in disc form or not. Pretty simple things. That work well with some expertise can do a good and cheap job. Now the photos. I apologize for the bad quality, but that's what i get from my mobile.

Mark the areas that will see some cut
   

Fire up the angle grinder and start cutting


That's what comes up from the first cuts. Like the music says "The first cut is the deepest" - Cat Stevens  


I'll be back

[crpt]

Lighter Piston - cont...
Oil holes for the pin should be countersunk again. In this case the countersink was deeper than original. Kept same diameter in those holes

From another angle


Another one


By the end we'll get something like this



Side view finished product

[lv2snwbrd]

Looks pretty good, I mean, I'm impressed.  I've never shaved metal from any engine part.  Maybe one day I will get a little courage and attempt to do something a like that.  Keep up the good work.  Oh, and awesome build thread!

[crpt]

----You may start with old parts just for training is a good way to learn the skills.

Hi all long time no see. Now I'm in Nigeria and my beloved KLR 250 is in Portugal. 
Really miss it here. Wherever you go in this country, looks like traditional Paris-Dakar.
After all i'm only 400km from Niger. In this country there are thousands of motorcycles everywhere.
But all 125cc from chinese brands like "Daylong" "Jincheng" and so on. They are all the same. 2 or 4 stroke.
But all utilitarian models with the same design. And used to limits unbeleviable for an european or american.
Maybe the best examples of use can be something like this:
- 3 persons on the bike, the rider talking on is cell phone, and driving in the wrong direction on the "express way". All this at the same time.
- 1 rider + 1 passenger + 2 goats 
And the best for last. The other day saw, and even now have dificulty in beleaving that's possible.
- 1 rider + 1 COW   

This small motorbikes are used for everything you guys can imagine, and much else. LOL

They carry absolutly everything from big logs, to agricultural products. Entire family economies depend on this crappy vehicules. By the way never saw, not even one japonese bike. Even small ones.
So when you guys start getting fancy ideas about motorcycles, things like, disk brake, six speed gear box, etc.
Remember this (bad) example   
Safety equipments are only a "mirage". At the most one t-shirt and just because of the sun. 
If I'm not wrong I think the other day saw "one" helmet. Some model that would have been outdated in the seventies.

While i was still in Portugal had the (stupid) idea of going back to Portugal, next year. In one of this small bikes.
Today was looking to one model, 125cc - 4 stroke honda clone, 4/5 gears, 20 liters gas tank!!! and one very long seat ready for 3 persons, drum brakes front and back...  Price new:120000$ Naira, something like 600€ or US$730. That's food for taught! 
Be well. I'll try to do the same. Let's see if muslins don't trow another bomb nearby.