Kevin Bergeron, a skilled paramedic and firefighter based in Alberta, Canada, is also well-known for his passion for motorcycle customization. While his primary occupation keeps him busy, he often finds time in his spare hours to indulge in building custom bikes under his personal brand, Berg & Co. His work has gained significant attention within the motorcycling community, and his projects are celebrated for their attention to detail and craftsmanship. One of the most remarkable creations that has drawn attention is a street tracker bike that Kevin built for a close friend.
This build showcases his ability to take a sturdy, utilitarian motorcycle and transform it into a unique and highly functional machine. The foundation of this particular project was an old-school 1984 Kawasaki KLR250, a bike known for its rugged durability and dual-sport capabilities. The KLR250 was initially designed to handle both on-road and off-road terrains, making it a favorite among adventure riders. However, with Kevin’s expertise and vision, the KLR250 would soon become much more than just a reliable dual-sport machine.
Kawasaki KLR250 Initial Steps: Dismantling and Planning
The transformation began with the complete disassembly of the Kawasaki KLR250. Kevin’s first task was to thoroughly assess the condition of the bike and identify areas in need of improvement. The bike’s powertrain, frame, and overall aesthetic were all areas that Kevin intended to overhaul. The rebuild would involve an extensive upgrade to enhance performance while maintaining the bike’s original rugged charm.
Powertrain Overhaul
The most significant change to the Kawasaki KLR250 came in the form of an engine upgrade. Kevin started by boring out the engine from its original 250cc to 330cc. This increase in displacement allowed for more power, enhancing the bike’s performance both on the streets and in off-road conditions. Once the engine was bored out, Kevin fitted it with a new piston and meticulously rebuilt it using fresh seals and gaskets. These upgrades were essential for ensuring the longevity and reliability of the engine, as well as boosting overall performance.
Intake and Exhaust Modifications
With the engine rebuild complete, Kevin turned his attention to the intake and exhaust systems. The intake system was upgraded with a Uni foam filter, which was installed over the refurbished stock carburetor. This modification provided better airflow into the engine, which is crucial for improved combustion and performance.
The exhaust system was another area that received significant attention in Kawasaki KLR250. The original exhaust was replaced with a custom stainless-steel pipe designed specifically for this build. The new exhaust terminates in a reverse megaphone muffler, which not only enhances the bike’s performance but also gives it a distinctive, aggressive sound. This custom exhaust was a vital part of Kevin’s vision for the bike, adding both style and functionality.
Frame Modifications: Customizing the Chassis
After addressing the powertrain, Kevin shifted focus to the frame. The original KLR250 subframe was removed to make way for a custom-built subframe. This one-off subframe was designed with a looped shape, contributing to the bike’s unique look. The rear section of the subframe was equipped with an LED light strip, adding modern touches to the design while providing practical illumination for nighttime riding.
The Fuel Tank and Saddle
Moving toward the front of the bike, Kevin installed a fuel tank repurposed from a Suzuki GS400. The use of a GS400 fuel tank was not only practical but also served to enhance the visual appeal of the bike. The tank’s shape and design complemented the overall aesthetic Kevin was striving for, and the unpainted metal finish added an industrial flair that contrasted with the more polished elements of the build.
The saddle, one of the standout features of the build, was custom-made by Kevin himself. The handmade saddle was upholstered with brown vinyl, which was stitched with a diamond pattern for added visual interest. The brown upholstery contrasted nicely with the dark tones of the frame and other components, giving the bike a timeless and sophisticated look.
Also Read: Tata Harrier 2025 Launch: Ultimate SUV Redefined with Cutting-Edge Features!
Kawasaki KLR250 Tracker-Style Front End and Suspension Upgrades
As a street tracker, the front end of the bike needed to reflect the style and performance expected from this type of motorcycle. Kevin added a tracker-style number board to the front, which is both a functional and aesthetic feature. The number board not only adds to the retro-inspired design but also serves as a tribute to classic tracker bikes of the past.
In addition to the number board, the front end of the bike features a pair of vertically stacked LED headlights. These lights provide improved visibility and modern styling, giving the bike a distinct look while ensuring safety during nighttime rides.
When it came to suspension, Kevin spared no expense. The rear shock was replaced with a premium WP shock, which offered superior performance compared to the stock shock. The WP shock is known for its durability and ability to handle rough terrain, making it an ideal choice for this build.
For the front forks, Kevin used the forks from a KLR650, which were outfitted with Race Tech internals. These high-performance internals allowed for improved handling and a smoother ride. The forks were mounted using revised KLX triple clamps, which helped to further refine the bike’s handling characteristics.
Upgraded Braking System
The braking system was another area that received a significant upgrade. Kevin installed a large 320 mm (12.6 inches) wave-style rotor, which provides improved stopping power compared to the standard rotor. The wave-style rotor is known for its increased surface area, which helps to dissipate heat and improve braking performance.
To complete the braking system, Kevin installed a high-grade master cylinder and a braided stainless-steel brake line. This combination of components ensures that the bike has optimal braking power, making it safer to ride in various conditions.
Kawasaki KLR250 Wheels, Tires, and Cockpit Modifications
The wheels were also replaced with high-performance components. Kevin chose 17-inch Excel hoops for both the front and rear wheels. These rims are known for their strength and ability to handle rough terrain, making them an excellent choice for a street tracker build. The wheels were laced with stainless-steel spokes from Buchanan’s, ensuring both durability and aesthetic appeal. Michelin Anakee 3 rubber was selected for the tires, providing excellent grip on a variety of surfaces.
The cockpit area was designed for both comfort and style. Kevin installed a new handlebar, which was paired with Brembo control levers for precise braking and throttle control. The handlebar grips were sourced from Biltwell and are made from brown rubber to complement the color scheme of the bike. On the left side of the bar, an underslung bar-end mirror was installed, providing a sleek and functional addition to the cockpit.
The only instrument on the bike is a classy analog dial, which is positioned prominently in the center of the cockpit. This simple yet effective instrument provides the rider with all the necessary information, without distracting from the minimalist design of the bike.
Kawasaki KLR250 Final Design and Color Scheme
The final color scheme for the bike is a mixture of dark red and unpainted metal on the fuel tank, with black predominating on the rest of the bike. The dark red adds a rich, deep tone to the design, while the unpainted metal provides a rugged, industrial look. Black was chosen for the frame and other components, offering a sleek and modern contrast to the rest of the bike’s features.
Kawasaki KLR250 Specifications and Components Overview
| Component | Details |
|---|---|
| Engine | 330cc (bored out from 250cc) |
| Intake | Uni foam filter with stock carb |
| Exhaust | Custom stainless steel pipe, reverse megaphone muffler |
| Subframe | Custom-built looped subframe with LED light strip |
| Fuel Tank | Suzuki GS400 (repurposed) |
| Saddle | Handmade brown vinyl with diamond stitching |
| Front End | Tracker-style number board with twin LED headlights |
| Suspension (Rear) | WP premium shock |
| Suspension (Front) | KLR650 forks with Race Tech internals |
| Brakes | 320mm wave rotor, braided stainless-steel line, high-grade master cylinder |
| Wheels | 17-inch Excel rims, stainless-steel spokes from Buchanan’s |
| Tires | Michelin Anakee 3 rubber |
| Cockpit | Brembo control levers, Biltwell grips, analog dial, bar-end mirror |
Conclusion
Kevin Bergeron’s custom Kawasaki KLR250 street tracker is a testament to his skill and passion for motorcycle customization. With a careful balance of performance upgrades and aesthetic modifications, Kevin transformed a reliable dual-sport bike into a striking street tracker that stands out both on and off the road. Every component, from the engine rebuild to the custom frame and premium suspension, was chosen to enhance the bike’s functionality while contributing to its overall stylish appearance. This build showcases Kevin’s craftsmanship and creativity, as well as his ability to breathe new life into an old motorcycle, making it a one-of-a-kind masterpiece.
FAQs
1. What inspired the design of this custom Kawasaki KLR250 street tracker?
Kevin Bergeron’s design was inspired by a blend of retro tracker aesthetics and modern performance upgrades. His late father’s influence and a desire to create a unique, functional ride drove his vision.
2. How does the modified suspension improve the bike’s performance?
The upgraded WP rear shock and Kawasaki KLR250 forks with Race Tech internals enhance ride quality, stability, and handling. These modifications ensure smoother performance on both rough terrain and paved roads, making it versatile and reliable.
3. Why was the Suzuki GS400 fuel tank chosen for this build?
The Suzuki GS400 tank adds a retro appeal and complements the bike’s overall aesthetic. Its shape and size integrate well into the design, enhancing the street tracker’s unique and timeless look.