I know the 300R muffler fits our KLX 250s, but how about the KLX 250R muffler? Looks like it has the removable endplate just like the 300's muffler. I can verify they use the same header. Last variable would be the location of brackets on the muffler. Anyone know if the 250R had the same frame as the 300R?

or, anyone used the 250R muffler/headpipe as a replacement?

 

For what it's worth, I bought a used full OEM system off of a KLX300. When I looked at the stampings on the muffler, it was marked with for model 'KL' and '250' along with some other characters I can't remember; it was not marked for '300' anything. To me this either means that I really have a KLX250R muffler, or that I have a KLX300R muffler but the design and markings were never changed from 250R to 300R. Either way, it fits just fine.

 

You know I did a deal with an Aussie, helping him to procure a tail pipe for his KLX250. He got ahold of a Honda CRF250R muffler with a special bent (aka got the muffler shop to bend it or used tubing to make it) connector pipe. To me, this is an interesting possibility since those kinds of pipes might be readily available on ebay since a lot of motocrossers swap out for different mufflers. Just a thought.

One other thought, which I did on my SR500. You can buy mandrel bent tubing bends from places like JC Whitney, JEGs and others. You cut up, fit, tack, fit, splice, tack, fit, then weld up your own pipe. It isn't as costly as it sounds unless you buy stainless. The trick is having someone who can TIG weld extremely well. My pipe cost $27 for the tubing, taking two 180 degree and one 45 degree bends to make the pipe. There's enough straight tubing to do the job fine. Just find out how big the trick pipes are and get that size of tubing. You could do the job and get it ceramic coated for around $200 if you have a good buddy TIG welder and get a good buy on a muffler.