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I have an '05 250 that needs an exhaust fix. The bike has been sitting for a while and the connection between the muffler and header has rusted apart (the one coming out of the muffler). Part of it has broken off so it doesn't reach the header now. How can I fix that connection without having to order another muffler? It doesn't look like you can just order and replace that part individually.

Initial thought: Use sheet metal and clamps to close the gap, then use a wrap around the pipe to secure it all.

Thanks
 

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That's odd, I thought the mufflers were stainless steel.

That connection is very close to the airbox and the rear brake reservoir. Both have been known to melt/leak due to leaky exhaust right where you describe. If you can't get a muffler shop to weld a new end on for you, I'd consider replacing whatever failed.
 

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I agree with shinnyribs. Visit a muffler shop or try E-Bay for a good used exhaust there should be several for sale as a lot of folks replace them.
 

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That's odd, I thought the mufflers were stainless steel.

That connection is very close to the airbox and the rear brake reservoir. Both have been known to melt/leak due to leaky exhaust right where you describe. If you can't get a muffler shop to weld a new end on for you, I'd consider replacing whatever failed.
shinyribs,
Take note that the OP said " '05 250 ".

I'm sure the air box is still in the Danger Zone of a failed Exhaust joint in that location, but the KLR250 has a mechanical Drum Brake.

E-bay or a cycle re-cycler for a USED exhaust System would be my suggestion.
 
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Paul beat me to it (again!);

- the KLR 650 silencer is indead a low grade stainless; I have no idea about the 250
- a clamp and chunk of sheet metal is a very bad idea due to the possibility of melting the airbox
- proper welded repair is an option if the metal is in good enough condition (i.e. cracked, not rusted off) but it's likely cheaper and easier to source a used replacement.

.....so basically, yeah; what Paul said! :)

Dave
 
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