Dual Sport for under $1000 - KLR Rebuild

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We rebuilt a Kawasaki KLR 250. We picked it up cheap, threw a few hundred dollars in part into it, a lot of labor and time and what we got was a great running dual sport that rides great for under $1000.
Curious about the parts we used on the bike?
Seat cover: amzn.to/2xuK6sb
Ram Mount phone/gps mount: amzn.to/3d8pBRa
Headlight Wiring Adapter: amzn.to/3dgSpav
Battery: amzn.to/3c1itpN
Front Fender: amzn.to/2WjQ1c2
LED Turn Signals: amzn.to/2WsucHc
Sealsavers fork boots: amzn.to/2Wn6RXA
Fuel Lines and Filters: amzn.to/3bWPl2S
Fork Seals: amzn.to/2SyW9w2
Rear suspension: www.motocd.com/
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Get this, and all the things we've used on DoItYourselfDad here: amzn.to/2z8Yly0
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Опубликовано:

8 сен 2024

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Комментарии : 126

@michaelschmidt4618 4 года назад

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

@tieoneon1614 11 месяцев назад

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.

@michaelschmidt4618 4 года назад

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

@Halotest100 3 года назад

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.

@DoItYourselfDad 3 года назад

Great bikes, this thing won’t quit!

@DanielGloverTheGreat 4 года назад

DUDE! I just found a KLR 250 for $400. Needs new wiring, lights, and plenty of body pieces. Glad I found your video.

@DoItYourselfDad 4 года назад

Sounds like you got a good deal! Shoot me any questions you have along the way!

@necomartin2059 Год назад

Got yourself a great deal with that bike and you made it look awesome, thank you for the video.

@dropsofink1336 4 года назад

I liked the old stock seat with the logo...but the new headlights, blinkers and new fender came out great! Cool 😎

@DoItYourselfDad 4 года назад

Thanks! The vinyl on the stock seat was cracking, and getting worse every time I sat on it so it had to be replaced.

@jamesconnor9142 4 года назад

My seat no logo. Is it not original?

@kushpaladin 3 года назад

@@jamesconnor9142 OEM ones have "KLR" "250" or "Kawasaki" on the side

@jhackett9482 3 года назад

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.

@DoItYourselfDad 3 года назад

Thanks! These older bikes are tanks!

@kentuckytycoon6964 4 года назад

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!

@DoItYourselfDad 4 года назад

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.

@danielcarroll5667 6 месяцев назад

Nice job Dad !

@DoItYourselfDad 6 месяцев назад

Thank you!

@oaktree71able 3 года назад

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

@beardedrancher 3 года назад

Looks fantastic. Great job. Love the baby klr

@DoItYourselfDad 3 года назад

Thanks! Love this bike!

@insatiable_mind 2 года назад

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.

@DoItYourselfDad 2 года назад

These are great bikes! Good luck with your search!

@revijapharidze2448 11 месяцев назад

Great project, please bring old front end back!

@DoItYourselfDad 10 месяцев назад

It’s back on there now

@TheDIYGuy-ut7ee 4 года назад

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.

@DoItYourselfDad 4 года назад

These are great projects, pretty simple compared to pulling apart a car. There’s a lot of resources out there on the net too!

@camilocienjuegos4633 Год назад

Pretty cool

@donaldheine6243 3 года назад

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.

@DoItYourselfDad 3 года назад

Awsome! Take a look at teh KLR650 rear shock swap. That should save you a few $$

@nanasconactitud 3 года назад

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!

@DoItYourselfDad 3 года назад

Thanks! Since the video I've gone back to the stock headlight and fairing.

@richardmorrison2686 3 года назад

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

@DoItYourselfDad 3 года назад

Yup! Love this bike!

@joang.4430 4 года назад

You continue to amaze me with the sheer breath of types of projects you tackle and do so well!

@SuperCapricorn67 Год назад

Enjoying the video ,thanks for sharing. Only thing I would do differently is rebuild the forks and fit new fork covers .

@DoItYourselfDad Год назад

Thanks! We did rebuild the forks and went with seal saver covers.

@grizzlysgarage8427 4 года назад

Good video bud keep them coming

@ColtonBlumhagen 4 года назад

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.

@DoItYourselfDad 4 года назад

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.

@mintyfresh9542 3 года назад

clean build.

@theluckycatcollective8788 3 года назад

I need more info on that box! Where can I get one like it?

@SystemIndex 2 месяца назад

That headlight isn’t just ugly. It’s hideous haha

@DoItYourselfDad Месяц назад

It didn't last long, it's back to stock now.

@hughjass4494 4 года назад

Next project: Ricochet skidplate. Well worth the money.

@DoItYourselfDad 4 года назад

Definitely! I’m concerned about smacking that water pump!

@michaelschmidt4618 4 года назад

I hope you still have the klr 250

@laprepper 4 года назад

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.

@michaelschmidt4618 4 года назад

Should have done a white seat cover, that would have been really cool

@dk.650 3 года назад

Not great for dirt but great for SM.

@tstonge4982 6 месяцев назад

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.

@DoItYourselfDad 5 месяцев назад

I came to the same conclusion as well, I swapped the headlight back to stock.

@Sertao2013 3 года назад

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 .

@DoItYourselfDad 3 года назад

Jets were stock size, bike runs great right now. Maybe at some point the jets were changed and changed back? Who knows?

@EliseEO3 3 года назад

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??

@humbertooliveira9263 3 года назад

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.

@HQHQHQHQHQHQHQHQHQHQHQHQHQHQHQ 4 года назад

When you put a different light source into your headlamp make sure it doesn't blind traffic! Otherwise you're *****.

@DoItYourselfDad 4 года назад

We definitely did. Another thing to remember is any time you tweak the suspension on these bikes the headlight needs to be re-aimed. Put 30lbs of stuff in the panniers and your headlight is right in people's eyes.

@HQHQHQHQHQHQHQHQHQHQHQHQHQHQHQ 4 года назад

@@DoItYourselfDad Yep, that's terrible...

@HQHQHQHQHQHQHQHQHQHQHQHQHQHQHQ 4 года назад

I wonder if there are chances to find this kind of bike alive nowadays for about 1500$...

@DoItYourselfDad 4 года назад

@@HQHQHQHQHQHQHQHQHQHQHQHQHQHQHQ There are a couple KLR250 facebook pages around, I've seem them on there that low. Most need work though.

@andreastrimatis 3 года назад

Where can I get the white light plastic (I don't remember how it's called)

@marcusnatschke4426 2 года назад

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.

@DoItYourselfDad 2 года назад

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.

@jasongalbraith297 2 года назад

I do like the front fairing setup, how can I go about getting one?

@DoItYourselfDad 2 года назад

I found that one on wish, the light wound up failing pretty quickly so I switched the light to another LED one off Amazon.

@thatoak9341 5 месяцев назад

Where did you get the storage crate for the rear fender ?

@DoItYourselfDad 4 месяца назад

It was from Harbor Freight.

@davidfloyd9962 3 года назад

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.

@DoItYourselfDad 3 года назад

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_ 3 года назад

@@DoItYourselfDad looking for the exact cowl , can u put a link ? That’d be great

@DoItYourselfDad 3 года назад

@@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.

@advancedautobodydydesign1036 3 года назад

I do not see a link to the headlight you used. Do you still have it?

@jack-sf4vk 11 месяцев назад

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?

@DoItYourselfDad 11 месяцев назад

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.

@trizzmotoktm4308 3 года назад

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 👍

@lookparp3356 3 года назад

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

@gqm5450 2 года назад

Great video, what engine brightener did you end up using? Have a KLR 250 that could use some love and yours looks great!

@DoItYourselfDad 2 года назад

Thanks! Best of luck with your KLR!

@gqm5450 2 года назад

@@DoItYourselfDad thank you! what engine brightener did you end up using?

@DoItYourselfDad 2 года назад

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.

@usmcct 2 года назад

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?

@DoItYourselfDad 2 года назад

I lucked out and didn’t need new gaskets for the carb, so I just cleaned it and reinstalled.

@markreiber4457 2 года назад

My battery went bad on mine but it runs ok ,will it make any difference with a new one?

@DoItYourselfDad 2 года назад

I really haven't noticed a difference. I've seen people delete the battery completely and replace with a capacitor.

@AREALAMERICAN 2 года назад

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 🤘

@DoItYourselfDad 2 года назад

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.

@909cool-oagents4 3 года назад

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

@DoItYourselfDad 3 года назад

The two things to look for is cam wear and blown rear shock. The rear shock is not rebuildable and $$$ to replace.

@No_one1776 2 года назад

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?

@DoItYourselfDad 2 года назад

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.

@laprepper 4 года назад

Did you do a compression check before you bought it or just kicked it over and kind of see how it felt

@DoItYourselfDad 4 года назад

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.

@theotrimatis8575 2 года назад

Can you tell me the name of the mask

@DoItYourselfDad 2 года назад

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.

@Padadventure 3 года назад

awesome work...very entertaining. what rear fender did you use?

@DoItYourselfDad 3 года назад

The rear fender is the stock KLR fender

@Padadventure 3 года назад

@@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.

@DoItYourselfDad 3 года назад

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.

@isjd9988 Год назад

Where did you got the white plastic on the front of the bike? At 6:15

@DoItYourselfDad Год назад

I got it off Amazon (dont have the link anymore). Its a generic fender.

@countryroadstakemehome 3 года назад

Can you ride these on the beach on the hard sand? Or would that ruin it? Thanks, nice bike too!

@DoItYourselfDad 3 года назад

Yes you can, though you'll want to clean the sand and salt off as soon as you're done to avoid corossion.

@countryroadstakemehome 3 года назад

@@DoItYourselfDad thanks heaps man.

@mikaswm1352 4 года назад

The music is a little loud. but in Love the video Good job

@freeman8508 3 года назад

Nice video! What trailer mechanism was that, that you hauled the bike on in the beginning of the video?

@DoItYourselfDad 3 года назад

Thanks! It’s a hitch mounted motorcycle carrier.

@jamesconnor9142 4 года назад

My KLR seat does not have KAWASAKI on side. Not original?

@DoItYourselfDad 4 года назад

All of the original ones I’ve seen have either said Kawasaki or klr250 on them.

@michaelschmidt4618 4 года назад

If you rub the side of the seat with carb cleaner the letters will disappear

@jamesconnor9142 4 года назад

@@DoItYourselfDad Disappointed not original

@nanasconactitud 3 года назад

Any chance to share where to buy that hard tool box?

@DoItYourselfDad 3 года назад

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.

@nanasconactitud 3 года назад

Thanks man. I’m in Chile, South America. We don’t have that store in here. Will keep searching for one on the web 👍

@nanasconactitud 3 года назад

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.

@Iirichil73 Год назад

nice bike awful front headlight and

@DoItYourselfDad Год назад

I agree, already went back to stock, just switched to an LED bulb for more light.

@vaughndrew852 3 года назад

I don't know about the front gard looks poxie

@Ninito19 3 года назад

I need a cdi to my 91 klr 250 anyone know where I can buit??

@gabrielkopp2036 2 года назад

You devalued that bike with in my opinion that ugly cowling and fender

@DoItYourselfDad 2 года назад

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.

@gabrielkopp2036 2 года назад

@@DoItYourselfDad sorry I'm just an origialist when to the older bikes .I don't like the modern look on them

@DoItYourselfDad 2 года назад

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.