Mufflers, Headpipes
and Spark Arresters
Most KLXers remove the butt-plug -- it's easy to do, adds 5 more horsepower, doesn't cost a penny and won't disable the spark arrester in your stock muffler. Even more power can be tapped from the stock engine with an after-market exhaust. But which after-market setup fits the KLX? Provides useable gains in power without waking the dead? Has an approved spark arrester? And isn't just blowing smoke? Here's a few pros and cons to help you compare the stock exhaust with currently available after-market systems, but keep these general rules of thumb in mind...
PROS | CONS | COST | ||
STOCK MUFFLER -- STOCK HEAD PIPE -- END PLATE ON STOCK EXHAUST => CLICK FOR PICS | ||||
Certified for 82DBA noise level. | Very heavy and very restrictive | Around $4800... :)) | ||
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STOCK MUFFLER -- STOCK HEAD PIPE -- END PLATE REMOVED | ||||
Acceptable noise level. About five more horse power Does not disable spark-arrestor |
Stock muffler is very heavy. Stock head pipe is very restrictive |
None, just take it off! | ||
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STOCK MUFFLER & HEADPIPE WITH CUSTOM END PLATE | ||||
Noise level? Power gains? Does not disable spark-arrestor |
Stock muffler is very heavy. Stock head pipe is very restrictive |
Contact Rob | ||
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BIG GUN EVO-X EXHAUST SYSTEMS CLICK FOR PIC | ||||
P/N 10-4313-K300 fits KLX250 and 300 3.5 more HP (claimed) USFS approved spark arrestor Less than 94 dBA w/Quiet Insert |
Rejetting is required | EVO-X = $479.95 | ||
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CRD EXHAUST SYSTEMS CLICK FOR REVIEW | ||||
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FMF EXHAUSTS -- Q2 & POWERCORE 4 CLICK FOR PIC | ||||
Part # 042000 fit KLX250/300 '94-'04 |
Noise level? Power gains? USFS approved? Lighter than stock? |
Q2 = $359.99 PowerCore = $299.99 |
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FOUR STROKE WORKS -- HEAD PIPE, MUFFLER & QUIET TIP FSW EXHAUST SYSTEM => CLICK FOR PIC | ||||
Under 90dB noise level. Much lighter than stock muffler. Significant power gains over stock |
Muffler/Arrester is not stamped but is approved by the USFS CLICK FOR PROOF |
Head Pipe = $154.99 Muffler/Arrestor = $299.99 Quiet Tip $64.99 (free w/pipe & muffler) |
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MUZZY STAINLESS SYSTEM w/ALUMINUM CANISTER CLICK FOR PIC | ||||
P/N 1014-00090 fits '97-'06 KLX-300 P/N 1014-00087 fits '97-'06 KLX-300 |
Noise level? Power gains? USFS approved? Lighter than stock? |
SLIP ON = $277.95 Standard = $427.95 |
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PRO CIRCUIT T-4 & Type 496 EXHAUST SYSTEMS CLICK FOR PIC | ||||
T-4 (4K94250/300) fits KLX250 & 300 Type 496 (p/n unk) fits KLX 250 & 300 |
Noise level? Power gains? USFS approved? Lighter than stock? |
T-4 = $337.95 Type 496 = $474.95 |
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Super Trapp and White Brothers no longer make exhaust systems for the KLX... |
CROSS SECTION OF CENTRIFUGAL TRAP
CROSS SECTION OF KLX-300 SPARK ARRESTER
US forest rangers use this procedure to check your spark arrester... USFS INSPECTION GUIDE