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...


Exhaust System Pros and Cons
ORIGINAL PROS & CONS ARTICLE

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...



Spark Arresters -- Theory and Practice
« JACK KRIZMAN's PATENT »          « JACK KRIZMAN's MEMORIAL »

CROSS SECTION OF CENTRIFUGAL TRAP






ZOOM INLET =>

<= ZOOM OUTLET

CROSS SECTION OF KLX-300 SPARK ARRESTER

US forest rangers use this procedure to check your spark arrester... USFS INSPECTION GUIDE