Any use of silicone would require a full cure for the application to be effective, before running the machine.

 

I use the Permatex copper colored High-temp stuff, and yes waiting a day to let it cure is the hardest part of putting a brand new muffler on.
Dan

 

Good call. This copper one goes much higher temp. But I'll try the red again because I still have some of it!
Permatex® Ultra Copper® Maximum Temperature RTV Silicone Gasket Maker

 

I'm going to do mine right before my fishing trip to NH (then there is no way I will be tempted to ride it)

 

How much does all of this cost? Did you install all these mods/upgrades yourself or did an authorized Kawasaki dealer install them? Anybody have links to Dynojet system? Interested to know if these parts can be installed fairly easily or if welding is involved. I'm a little apprehensive about meddling with the airbox, but if it's straightforward, I'd give it a go. Haven't even got 300 kilometres on my KLX250S yet.

 

I went with hmf exhaust and rejetted the carb with the dynojet system. This bike is so much better now. But the exhaust tend to get hot and pop on decel. If i remove the air intake system will it help or will it hurt the performance?

 

That flat spot is driving me crazy, doesn't go away until the bike is fully warmed up. I'm getting the same combination of parts as you in the next week or so....can't wait!

 

Dynojet - ~$55
HMF exhaust - ~$280
Kouba Screw - ~$25

All a relatively simple do it yourself job.. just take your time.

 

This is the DynoJet kit you want:
Amazon.com: Dynojet Research Intake Performance Kit - Stage 1 2206: Automotive
Here is a great seller HMF seller:
HMF Kawasaki KLX250 (06-10) Polished S/O Exhaust | eBay
And I have an extra Kouba screw that no one has scooped up yet.. $23 shipped.

 

Are you speaking of the emissions air injection equipment? If so, it's designed to let air into the exhaust stream so that the stock catalytic converter can do it's job in cleaning up unburned fuels. I removed mine and it helped reduce pop and keep the exhaust pipe temp much lower.