Looking at the copper exhaust gasket against the cyl head exhaust port the inside diameter was close to the same size, not so on the exhaust header flange. On the stock header there was a weld bead inside the header that obstructed the flow. So I ground it out to the I.D. of the copper gasket. My final jetting was a 40 pilot and a 132 dynojet main 1.5 - 2 turns out on the kouba fuel screw.

https://www.kawasakiforums.com/forum...4&d=1237863539
https://www.kawasakiforums.com/forum...6&d=1232949750

Did it help, I think so. But any mod to help boost the stock 18 hp I didn't overlook.

Any other ideas?

Anyone need a stock header thats been modified?

 

Ideas to boost HP? Uhhhh you have over 400 posts and must have read that the usual suspects are jetting, full pipe and air tweaks. Those 3 are essential for opening up the KLX.

 

Big bore. Quit wasting time/money

Seriously. Get the exhaust, jet kit, and big bore, and be done with it.

Oh, and read the hundreds of pages of the same exact question you just asked too

 

fluxcapacitors (pipe) and warpdrives (bigbore) help a lot.

 

+1

I also got a Husky TE300 to play with too. That may not count as a power boost to the KLX but...

 

Well what you call a waste of money I call perfect.

 

Tire pressure & oil threads are what the 400+ posts came from.....