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I'm fairly positive that the header pipe will fit, there might be differences in the mounting location for the muffler though. I know that Kawasaki did make changes to the aft part of the subframe from the 06-07 to the 09+ klx.
It shouldn't be difficult if there's differences in the mounting tabs. I put a 06-07 klx 250 exhaust on a klx engine that I swapped into a klr250 frame. I just made some 3/16 steel relocation tabs.
You can see that I used two out of the 3 muffler mounting tabs. I made them out of some simple 3/16 x 1 flat steel. Shouldn't be too difficult if you have to do something similar for the different year klx's.
Very quick thinking on your part to getting that bolted up. I was looking at Partzilla comparing the part numbers, the illustrations show those parts looking very similar in mounting points. Thanks for the pics, shows how easily it can be done 👍 Looking at the passenger peg mounts, those could be adapted to many other bikes if needed. I’ve never ridden a klr250. The conventional forks & drum brake take me back to the old Yamaha days dt-1 at-1 rt-1.
