Anybody know how different the exhaust systems are for a 2003 vs. 2006 klx250? ie will a 2003 slip-on fit a 2006 bike?
thanks
doc

 

I'm pretty sure there are no slip ons that work with the 06 other than the HMF slip on.

 

Yeah, I'm beginning to see that the choices are indeed limited. In any case, it wasn't 2003, it was 93-96 fitting a 2006:


http://www.dgperf.com/mx/MXproductsD...andID=Kawasaki

It looked like a pretty cool pipe for the money. Since one of the major reasons/justifications for my buying the klx is to save gas money, it's kind of hard to spend $500 on an exhaust system for a Muzzy or Big Gun. Still, makes me wonder how close a fit this DG would be...my friend/business partner is an awesome welder...are 96's all that different? I pulled up a pic of one, and the engine/exhaust system actually looks identical. Whatcha think?
doc

 

The headpipe length and flange diameter are different. I have an exhaust from the 250D, has no catalytic converter and the exhaust outlet is the same size as the headpipe diameter, 1.3 inches. I made a baffle plate to drop it down to 3/4 inch to quiet it down to a more tolerable level. For the headpipe and muffler they go for about $40-$60 on e-bay. They are less restrictive and have a better sound as well, suited my purpose perfectly. It also looks completely stock except the baffle plate on the end. If you haven't seen it, do a search for my post called 300 exhaust or something like that, its a few pages back. I also have a sound clip on there with the baffle off.

 

fixed [8D]

 

Thanks Mav. Do you know if there is a US Staintune vendor?

 

I ordered the HMF as I want to retain the original head pipe w/heat shield.
I will post a report when I get it installed.

 

Awesome, I look forward to your report as HMF wouldn't supply me with any info other than the locked thread on their site. I asked if they could get a soundclip and it was an emphatic no we don't have any and don't plan to take any. The only info they had on it was the dyno runs.

 

Yup, I'm anxious to get in installed (w/quite core) I expect it to be very close to either of the other systems most are installing. I'm convinced the big issue with the stock system is the "cat". I tried some of the muffler outlet mods and the sound is still very "rappy".
I also will retain the stock head pipe as the larger diameter header will loose some bottom end torque becasue the full systems are designed for the 300. I had good converstaions with the HMF guys. Only bad thing is they build to order, so the wait time is approx 2 weeks yet.