Bought a 250 motor and started a new project - Kawasaki KLR 650 Forum
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post #1 of 4 Old 10-05-2019, 03:24 PM Thread Starter
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Join Date: Oct 2019
Location: Fort Worth, TX
Posts: 3
Bought a 250 motor and started a new project

Hi all,

As the user name implies, i'm kind of a junk yard rat. I found an engine case for a KL250D for about $60 in a junk yard that was missing it's cylinder and cylinder head. I figured it would make a fun rebuilding project. I've rebuilt other motors in the past but this will be my first Kawasaki. Eventually I may buy a KLR frame to go around it but for now I just want to get the engine put back together. I know this is a 650 site but I hope you can make an exception for a new 250 owner.

I'm looking forward to learning alot.

Starting with, where the heck can I find out what year of bike this engine came out of? Nobody seems to be able to give me a straight answer. The engine code is:

KL250DE039896.

I want to start finding cylinders and heads but I'm not sure which year to start with.

Thanks in advance,

RJ
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post #2 of 4 Old 10-05-2019, 04:35 PM
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Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,541
Kawasaki quit listing the beginning Engine number with the beginning VIN for each year model in about 1989.

So I can tell you that it is newer than 1988, which engine number began KL250DE019501 according to my '86-'88 model recognition book.

Giving 1500-2500 per year of production, I'll suggest that 1998 model year would possibly be close enough. They did not change much if any!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 4 Old 10-05-2019, 09:56 PM Thread Starter
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Join Date: Oct 2019
Location: Fort Worth, TX
Posts: 3
That's great news! Thanks for the info. I won't worry too much about which cylinder/piston/head combo I end up with. Now all I need to do is find a good repair manual and I'll get to work.

Gracias!
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post #4 of 4 Old 10-06-2019, 01:56 AM
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Join Date: Jan 2011
Posts: 4,332
If that's a KLR250 engine (can't tell, from the engine number; pdwestman probably can), this may be useful:



You can get this manual from Kawasaki (I think; KLR250s were not sold in the US beyond 2005 models, AFAIK.)

The catch: This manual is a SUPPLEMENT; it references the KLR600 (yes, KLR600, not KLR650) "base" manual; don't know if Kawasaki has any of these in stock any more, but bet they do. A work-around if a Kawasaki KLR600 manual is unavailable: A Clymer, pre-2008 KLR650 manual, instead of a KLR600 manual.

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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