As far as drilling the stock pipe, I like the option to be able to go back to stock if I want. I ended up making a plate with a hole for the 300 pipe. It replaces the stock spark arrestor. I tapped the hole so I can add or remove a fitting. With the fitting in, the bike is as quiet as stock. With the fitting out, it just makes just enough noise to sound like a motorcycle. With the plate removed, the bike is loud, too loud for the places I ride. The 300 pipe makes more power than the stock pipe. When I race my brother, who has another 250S, I drive by him everytime. Everything is the same between the bikes except the pipe.

 

dazjr, did you have to make any carb adjustments with the exhaust setup you are running?

 

Ran a Trapp on the KLR650 for about 5k miles. Loud piece of crap. Didn't notice any power gains, just LOUD!

I was reading somewhere that a 'stroker' head pipe with the stock muff is a good package. Now I can't find 'stroker'.

 

I read the same thing at Planet KLX. Although the exhaust review is for the KLX 300, it might be useful to everyone. Here is the link:
http://www.planetklx.com/techtips/exhaust.shtml

 

Planet KLX is a KLX 300 site but has some good tips on free mods that apparently many people have been using for the KLX 250. Here is another link for those of you who may be unfamiliar with the website.
http://www.planetklx.com/techtips/free-mods.shtml

 

I have done all the free mods except drilling the airbox. Actually, I did the mods before the pipe. I tried a bigger main after the pipe, but ended up going back to a 120. I couldn't tell a big power difference and my gas mileage sucked. Thats when I ran out of gas on the highway at 78 miles. Now I my gas mileage is between 50-55 avg. The 120 is a little lean for 40 degree and under temp, but I have been able to get away with it because of the warm winter.

 

That head pipe is available from FourStrokeWorks now.

Todd

 

Thanks for the link, will the muffler fit right onto the KLX300 Headpipe they have listed?? How do you think this header with the original muffler will be performance wise against a full Muzzy?? This is close to $150, but man, its so hard to choose what I want, performance or stealth. Take for instance today, I went riding and had a blast, I found a place off to the sides of the main trails that seemed like it was private, but I couldn't tell. Anyways it was a blast riding those trails, they were incredible. I also realized that I had an incredibly quiet bike, and I doubt anyone heard me back there. I'm sure with a muzzy on, the performance would be killer, but then I have no close trails to ride because I would be alerting the whole neighborhood Desicions, Decisions??

 

The Muzzy was under $400 delivered. Hoorah for single cylinders! I spent $almost $600 on a headers and exhaust for my CBR600. I traded in a $5000 sportbike on this thing, so I can spend a little to get exactly what I want.

I spent twice that on descent helmet, googles, boots and other ridign gear. I still have my priorities. Staying in 1 piece is still top of my list.

 

This is my reason for not buying aftermarket muffler ... yet. Noise. Where I live I cannot have a noisy system and I don't want to be responsable for having tracks closed down because of noise. There are enough noisy bikes already. I'm still leaning towards the aussie Staintune for several reasons.
1) Quality, it appears the Staintune is very very high quality and will never need replacing
2) Never needs to repack the muffler, very appealing to me
3) Made in Australia, like a lot of you guys that are proudly American I am proud to be Aussie and I do try to support Aussie companies

Against the Staintune are

1) Price, at $800 Aus its bloody expensive, however I have not found many others to be much cheaper
2) Noise, seems it is still a bit vocal even though better than a lot of others

These are my reasons and as such may not apply to other people