Who makes the header on the right. It looks to be aftermarket, not oem.

 

Read again. I think he made that himself.

 

I built it myself. At that time, only Muzzy and Big Gun were making full exhaust systems for the KLX. I'd had Supertrapp systems in the past that I liked, so I got an IDS2 slip-on kit for the KLX300 and made the headpipe. I bought a KLX300 headpipe originally, but then used the flange and end ring to make mine own.

https://www.kawasakiforums.com/forum...ent-note-11692

https://www.kawasakiforums.com/forum...part-2-a-11924

 

Pictures labeled.
"Stock is on the left, 300 is on the right..."

Nice job on the header. I did not want anyone to be confused and think the header on the right was a stock 300 piece.

 

That 300 pipe looks like a larger diameter than the one I have. I should still have both. I'll pull them out tomorrow and look. I thought I measured them, and they were identical, except for the outlet diameter.

 

Since I had to close up the barn... thought I'd look for them.

I think I misunderstood your post, but here's the 250 and 300 pipes. The 300 (on bottom in first pic) is in fact slight longer.

 

Well, it seems we're both probably right Zomby. According to the fiche on ronayers.com, there were 2 different headpipes for the KLX300. From 1996-2004, the KLX300 headpipe was part no. 18049-1689. From 2005-2007, the part no. for the headpipe is 18088-0034. Plus, from 2005-2007, they used 2 different mufflers - one for US bikes and one for Canadian bikes.

The clamps for the joint between the headpipe and the muffler are different part numbers too between the 2 headpipes, leading me to think that there is a size difference in the diameters.

I think the headpipe I had came off a 2001. Maybe yours is one of the newer ones?

I always wondered why slip-ons for the KLX300 were listed from '96-'04, even though they were produced until 2007. Now I know.

 

If I change headers or exhaust is my warranty voided?

 

If they do void your warranty, then bolt the original parts on before taking it back to your dealership!! I got about a days work to get mine back to factory standard condition should any warranty work be needed :-(

But on the other hand parts are cheap in Thailand & dealership labour charge at about $17/hour.....so I'm not loosing any sleep about voiding it......so far!

 

The dealer I bought my bike from is adding my jet kit. I also ordered my powerbomb header and pro taper handlebars from them. They informed me my warranty is indeed safe.