An easy exhaust leak fix is just to buy the header too........................of course that costs more money.

For some reason, FMF built the muffler to fit the 06-07's really well and then just kind of made them fit 09-10's. Just them being lazy I guess.

A little leak isn't to terribly bad, but sealant is cheap and easy.

Oh yeah, these engines are LOUD, which is why I think the Q4 is the most common muffler out there used on our bikes.

 

Thanks Joel and BigSky. I just went out and re-did 'er. I think I got a snugger seating and used more sealant. I have to be gone over the weekend so I won't start it until Sunday late afternoon, maybe that extra curing time will help too.

Joel as far as the airbox goes, I read about people having melting issues so I used some ACE hardware metal repair tape ($5.99) it is good to 230 degrees I put about 4 layers in a nice criss cross fasshion over the parts where the airbox is close. I think it'll be fine.

I haven't rejetted yet but that may come in the future and definitely if I add the power bomb. I am going to an ADVrider rally in Death Valley in March and hope to meet some mod'd KLX owners to compare a jetted / headed bike to mine.