I hadn't seen any other posts about this issue, so I thought I'd mention my fix. I recently bought this fully modded '06 KLX250 that was in excellent shape. However, the muffler mount frame bracket was broken which I've seen as common on dirt bikes over many years. This is often an easy damage point from either vibration or a crash in just the right place. In the past on steel frames, I've just gotten a better bracket welded back into place, and this has always worked excellently.

I noticed on this bike that there are two conveniently placed bolt mount holes of 8mm size that could be utilized for a bolt-on muffler bracket. I used some 1/8" thick aircraft grade aluminum...came from our local Lockheed salvage pile...to hack out a plate and modded it to fit the frame and two bolt holes. It mounts easily to the existing holes, and then I drilled it for the muffler mount hole. The thing I like about this setup is that I can easily hack out a new one if needed in the future without putzing with welding. It's obviously no rocket science project, but just thought I'd share it if the same thing happens to any other KLX owners.

 

Good fix!! Will file it away in the memory, just in case.

 

That's pretty good. I just welded a washer onto the broken piece that still had the welded nut on it then welded it back onto the frame. I like your solution better. Next time that piece breaks I'll do your fix instead. Thanks for sharing that.

 

Very Cool of you to share the Info.

 

Yep mine broke in Oregon in July, I sort of made a bracket, but it still wobbles. I need to improve it some. Nice job there TNC.