header pipe difference

[bansheedave]

I have a stock pipe that is a 99. I purchased a used pro circuit that was supposed to be for a 99 but it doesn't fit. It is slightly off going into the cylinder causing the stinger to be off location. So I can't get the muffler to mate up. Is it possible the pro circuit pipe is bent or not the correct pipe?

[Foxx4Beaver]

if you look at the numbers on the PC pipe you just got....you can match them up on Pro Circuits site....
here's the '99...where it says Item PK99250P, that's for "'99 Kawasaki 250 Platinum", for an '01 the number would read PK01250P...
here's the '99...

http://www.procircuit.com/platinum-pipe-kx250-99.html

here's the complete list....

http://www.procircuit.com/platinum-pipes-kawasaki.html

[bansheedave]

I just looked. It is for a 99. It must be slightly tweeked.

[Foxx4Beaver]

yeah it sounds as though it's tweaked...especially if it's got any decent sized dents and battle scars.

[bansheedave]

It had a couple small dents around the name plate. One came out pretty easy and the small one behind the plate will come out just as easy once the plate is removed. I just have to figure out how to get the pipe lined back up now.

[Foxx4Beaver]

I just have to figure out how to get the pipe lined back up now.

depending on how bad it's bent, it can/could be tricky...going very slow is critical...a decent size bench vise is useful.
our member Joko has a place that fixes pipes if it's bent bad....

http://www.fusiononeusa.com/

[bansheedave]

Alright. Here are some pics. The pro circuit pipe is a 99 for sure. Now that I had some better lighting to see the difference.  The stock pipe is not a 99 like I was led to believe. It does not follow the same path as the pro circuit and has a definite length difference.  Can anyone give me a rough idea what year the stock pipe may be? 94-98 possibly?


I want to get a new or better than stock that isn't all dented up. I worked some of the dents out but the metal is creased. And I can't use the pro circuit pipe so it has to go.

[Foxx4Beaver]

does that stocker have any numbers on it at all that could possibly be used to decipher it's year?

[bansheedave]

No. I looked. Just the stamping that it's not noise compliant blah blah blah.

[DoldGuy]

Dave,

I believe your stock pipe is either a 2003 or 2004 model....

The 1999 (new frame year) pipe will fit the 1994-1998 (older frame). The 94 pipe has a larger inlet diameter versus 95 & up, also if memory serves, was "Black" unlike later years with the "charcoal gray" color. The 1999-2002 share the same chassis/pipe fitment...

One of our members here has the 03 & 04 models & might have an extra pipe or pics to share.

Hope this helps

DoldGuy

[bansheedave]

Thanks for the information. I am going to believe it has to be an 04. The 03 mounts different.  The only model that mounted near the slip joint and not on the top of the expansion chamber. So I will check out the 04 pipes. Hope the other member you had mentioned will read this and chime it.

[shrubitup]

Thanks for the information. I am going to believe it has to be an 04. The 03 mounts different.  The only model that mounted near the slip joint and not on the top of the expansion chamber. So I will check out the 04 pipes. Hope the other member you had mentioned will read this and chime it.

I don't think I'm the "other member" but I did put a full 2004 stock pipe on my 1999 KX250. Thread here.

http://www.kxriders.com/forums/index.php/topic,13772.0.html

[bansheedave]

Thanks for the information. I am going to believe it has to be an 04. The 03 mounts different.  The only model that mounted near the slip joint and not on the top of the expansion chamber. So I will check out the 04 pipes. Hope the other member you had mentioned will read this and chime it.

I don't think I'm the "other member" but I did put a full 2004 stock pipe on my 1999 KX250. Thread here.

http://www.kxriders.com/forums/index.php/topic,13772.0.html

I built a blaster using my kx motor since I wrecked my bike. I picked up the stock pipe and built the frame around the motor and pipe. everything fits with tight tolerances so I need a year specific pipe. the 99 just will not fit. the stinger of the 99 lays on the frame and actually hits the head of the motor. weird.

[Foxx4Beaver]

worst case scenario...you could bust out the saw-zall and cut the pipe in half, or where ever need be to modify it so it clears everything nicely, then weld it back up.
might be the easiest and cheapest route...guys do it all the time on conversions.
 

[bansheedave]

I am thinking of just cutting the stock pipe open and bang out the dents from the inside and weld it back up. I would rather just sell the pro circuit pipe the way it is now.