Try purchasing the sheet metal, the tubing, bending and sawing the tube, roll forming the sheet metal, fabricating the end caps, building a weld jig..and then sell it for $200 bucks, and you want it to be perfect ha ha ha. Do you see the slots in the seat brackets? Kawasaki put them there because THEY couldn't make every single one "perfect". You should stick to stock motorcycles, you'll be a lot happier.

 

email sent with pics marc11

btw...I reinstalled it yesterday and this time I did twist it at the clamp where it joins the headpipe and now the 1" spacer is a little extreme. A 1/2" spacer would yield ample clearance to the fender now.

I can only attach 1 pic per post so bare with me as I make 4 posts

 

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The quality of the muffler looks great, the welds are clean and very professional looking, the only problem I see is the mtg bracket could be placed a 1/2" back, other than that its a damn good looking muffler that sounds great (according to martys clips linked below). If you can live with the 1/2"-1" spacer then this is a helluva deal.

sound clip of the HMF with quiet core insert and without on the klx250s
https://www.kawasakiforums.com/m_94454/tm.htm

 

I realize you shouldn't have to, but I bet if you took it to a custom exhaust shop, they'd be able to fix it up for you for probably less than $20 to $40. Several folks here have fit slip-ons / pipes from entirely different bikes on their KLX250S's and they take them to a shop which will tweak the bends and flare the mating ends to match. You might be surprised at the capabilities of a good fab shop.

 

Actually with just a 1/2" spacer its almost a non-issue anymore. Hell I may just keep it...sure looks good polished.



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