KLX's - a shared disease

[sa63]

I rode one recently for the first time (stock) and ill vouch for the handling.. fantastic.. no let off on the throttle, a bit of giant killer with the corner speed.


I wonder what one would be like with a worked xr 200 motor, to keep the light feel, as I did do a project job with a xl 500 motor a few years ago, but didnt really like it, the standard bike is a better unit..

[cloggy]

 I'm presently on a P/0 needle jet  [needle in leanest clip] 130 main and  down one size  on the pilot too to 25
 The only relevant engine change I presently  have is the bigger bore exhaust. Allens Performance made the needle jet. That's two sizes down from the standard P2!
 Although everyone says the airbox is restrictive the airbox intake is several times bigger than the Suzuki SP370 and DR400 examples, though there is less room round the filter. On these particular oval bore carbs I have found the same on the Suzys and the KLX. The more you derestrict the exhausts [and on the Suzy the inlet] the leaner you need to set the carb. The SP370 uses the same 32mm size/type carb, albeit with a few changes. If you go to a bigger carb it's probably going to bog even worse. By the way the SP370 engine uses a much smaller main jet than the KLX.
  I'm a wobbler and on a enduro course I'm faster on the KLX than I am on my dream handling Mann TT, there's not enough power to get me into trouble. On a  scramble course I'm faster on the Mann.
 Lastly I've fiddled with the float height on both my klx carbs. They seem to come overly rich. On one there was no sign the carb float tab had ever been anything  other than in line with the rest of the brass, which was way rich and possibly why the doner bike had little use.
 Hope this helps, your bike makes my ones look like they came out of a skip!
I'm  not surprised the xl500 engine overstressed the frame. I had thought perhaps the 250 version was a better bet.

[cloggy]

 I see I've given the kiss of death again...
 Just picked a metal KLX tank from ex national champ Andy Roberton. He and Steve Plain built a KLX for the welsh 2 days. He said it was as flat as a fart so they sent off to White Bros for a kit. The kit comprised of a cam, a 34mm? Dellorto, a 280 cc piston, and an exhaust with a Supertrapp. He said it revved to the moon after all that. Steve won the 4stroke class on it.
 The KLX being a stretched 200 I don't suppose it lasted that long though...

[grouty]

I thought I would keep this in here as it seems to be the current topic.
Being lazy (I've had 18 months to do this) the new big bore front pipe is done this week, and I have a few days off next week. As prep I thought I would clean up the carb. One job that needs doing is the choke button. When pulled it just comes off as the wire clip has long since gone west.
Where can I get a new choke kit with plunger complete ?  Is it the same as anything else fitted to another Mikuni ??
Bits for these carbs seem to be thin on the ground. I will try Cradley Kawasaki tomorrow, but I don't hold out too much hope.

As soon as I have the bike back I will post a picture of the new pipe complete with Husky 430 silencer. I hope it will be quiet enough.

[cloggy]

 I think the internals may be identical to the sp370 dr400. The problem is that the suzy carb has a fulcrum whereas the kawa carb has a pull knob. One could convert one to the other but it wouldn't be original
 If it's a part deep in the bowls of the choke assembly that you need I have several spare  suzy mikunis I could raid

[grouty]

Had a bit of luck with Cradley Kawasaki. The complete choke assembly was still available as NOS, along with a few other bits for the carb rebuild.
I will post a picture of the new exhaust pipe with Husky 430WR silencer later. It's now just a case of time to get it back up and running.

[grouty]

Getting there .......





The silencer is from an 81 Husky 430WR

[cloggy]

 Yeh they told me the main jet I wanted was not available, and then sent me it coded unavailable! [132.5]
 I've had to jet right down to get the bike running right, a leaner idle, two sizes down on the needle jet [p-0] and needle on leanest clip. It was using oil, I re ringed it and the lack of oil richened the mixture. It's currently running the standard cam so the only non standard part is the optional bigger bore exhaust. It runs cleanly and crisply through the carb settings but there's a lukewarm hiccup  when transitioning from idle. I have to quickly turn the choke off as I open the throttle so I'm pretty sure it would take a leaner cutaway. Your bike looks nice. What rear shocks are you running and did you get a new seat cover?
I've been told that the metal tank UK model used a shorter seat but on  measuring them they proved identical.

[grouty]

The rear shocks are the standard ones it came with when new. I try to look after them as much as is possible. They still work as they did when I bought it in 82.
Yes, new seat cover from MXM. They seem to have a bit of trouble with the wording "short seat cover" but we got there in the end. Seeing as I was the one that gave them the original pattern in the first place !
The UK/steel tank versions do have a shorter seat. The seat foam is the same as the long seat version and are available new. All you have to do is chop about an inch or so off the front.
I will need to get my head around the jetting as soon as it's up and running again. I will start with the standard jetting, and go from there.
Not sure how much difference my Megacycle cam will make to the settings you are running. My compression is up around 10.5:1, or maybe a tad more. It certainly won't run on 95 Ron fuel ! Even with the standard cam and exhaust I was running a mix of super unleaded and 114 octane race fuel with the MTC piston.

[cloggy]

 I measured the seat bases and they were the same but I didn't check the top of the seat. I'll do that. Both my seat covers are knackered so that's on the list.

[Paulsky]

Hi VMX42, below is a pic of the new shock mounting you asked for
I put a Mikuni TM 36-68 carb on the bike and it is a whole lot better, revs quick and is a little faster as well, also jets are available for it







Cheers for now

[sa63]

Great Job, Paulsky,

big drive up to Syringa for the debut!

I have acquired an amazingly original if sun faded klx (even all the electrics work) but the airfilter has fallen apart and they arent jumping out at me on the internet, is anything available or a crossover option??



thanks in advance.

[grouty]

O.E air filters seem to have gone the way of the dinosaurs .... extinct !
I bought a new genuine one a few years ago from CMSNL in Holland. The filter was perfect, the cage to go with it looked the same, but was too long by about 40mm. Both of these are now listed as no longer available.
I am now in the process of finding/having new ones made. I will also need to get the cages made too. Unless some kind soul has already done this. In which case I am ready to part with some money 

[Gday]

You can buy klx airfilters from unifilter Australia . (nice job) Glenn

[sa63]

I looked at their website, only saw the kl 250.
Will check again . thanks

Done and ordered

thks again.

BTW -BK performance in Brisbane has quite a few gaskets / levers etc very reasonably priced