I have to figure out how to do this.. I think I saw a tutorial on here somewhere.. but for some reason I was still confused.. hahaha

 

Pretty simple on the '06. Remove all the emission crap (hoses, valves, connectors) between the airbox and the exhaust and block off the holes on both ends. You'll find a tutorial under the FAQ sticky.

 

It was about $275 for the pipe and $60 for the dynojet system. The exhaust was fairly simple just un bolt the old exhaust and loosen the clamp where the head pipe and exhaust meet. Pull that exhaust free. When i put on the HMf exhaust it went very smooth i just notched the hole for the bolt up by the seat because the exhaust was just about a 1/4 of an inch to short but easy to do. But rejetting wasnt the easiest. The hardest part of the process was getting the carburetor out of the frame. What a tangle to get to but after that it was pretty easy to follow the directions from dynojet. There is a step by step process by hmf just look up kawasaki klx carburetor removal. Follow the dynojet instructions though for jetting.

 

Something to keep in mind here....most aftermarket mufflers attach to the frame at only one point. That tab will get fatigued over time and some have had it break off during a ride. Watch it closely. Consider strengthening the tab by welding on some additional support. May not be as much as an issue for street riders.

I got my HMF slightly used off ebay for $120 plus some shipping. They show up occasionally. The HMF must be one of the louder variety of aftermarket muffs because I see used ones there more often than the others. Dynojet kit was closer to $50 from my local independent shop. While you're in the carb, read up on cold starting problems and think about drilling out the starter jet to 0.018".

 

The HMF is loud (and slightly longer than I would have liked it to be)

 

Good god of god good. Much respect to riders who install this stuff on their own. To me, the DJ kit looks and sounds horribly complicated. Should have taken mechanics, rather than woods, in high school shops class. Checked out the HMF walk through for Dynojet upgrades (Kawasaki KLX 250 slip on - HMF Engineering Forums) and all I could do was laugh... like I'm going to try disassembling my KLX without any previous experience. I'll probably just stick to the regular religions of bike maintenance, those being oil changes, air cleaner cleansings, as well as keeping vigilant of tire pressure, oil level and brake fluid levels. Just not prepared to start taking things apart, drilling stuff open and meddling with the gods. It will probably cost me an extra couple hundred dollars to have a licensed mechanic do it for me, but it will be worth it in the long run. By the way, if you install a slip-on, do you need a Dynojet kit? Also, if you buy a slip-on, are most slip-on's compatible with stock headers? Thinking about ordering FMF Q4 muffler, powerbomb header (if absolutely necessary) and getting authorized Kawasaki mechanics to install the Dynojet 2206 kit. Seems to be a good combination that's recommended by many rider/forum-goers. Probably will run upwards of $500 to $600, but perhaps peace of mind is worth it. Honestly though, if I tried doing all this myself, I'd end up rolling around in my garage trying to kick myself in the face. By the way, Kawasaki service personnel told me today that the muffler upgrades and DJ kits don't make much of a difference in terms of performance, other than helping the engine start when cold and emboldening the throttle, but it certainly improves the sound and look of the bike.

 

Well.. you do NOT need an aftermarket header.. Some say the FMF header adds to performance/others say it does not.. Until I see hard evidence I will stick to my stocker and save the $200.
Any aftermarket exhaust will fit your stock header unless noted otherwise.
The DynoJet kit and exhaust make a huge difference in smoothness and start up.. performance-wise - maybe a little bit..

 

On most bikes, adding exhaust and jet kit doesn't add much power, but on the KLX, it adds a lot of power. You will be glad you did it.

You would laugh at yourself if you knew how easy it was to do a jet kit. If you can turn a screw driver, you can do a jet kit. It sounds complicated but really is very simple. Although, if you feel better having someone else do it, than go that route.

The best way to get to know your bike though is to tear it apart. If something ever breaks out in the wild, it helps if you know what you are doing.

 

 

I think you may have looked at the HMF forum thread on jetting and adding their slip-on and removing the airbox snorkel. Their dyno test showed a 18.3 to 20.8 horsepower increase (14%) and 13.0 to 14.7 torque increase (13%). In my book, this is a significant improvement in performance. Other similar dyno charts have been posted around here. HMF used Kawi jets and shimmed the stock needle. The DJ needle is more aggressive than stock.