'99 KX250 Pipe Problems

As long as you remove the 'platinum' finish, you shouldn't have any problem running a small bead along the crack. Maybe you could paint that area with clear with some spraypaint so it won't rust?

As far as leaking from the cylinder, put some hight-temp silicone around the joint and you should be good to go. You don't need new pipe springs unless they're broken, they don't tend to lose there tension. If you do get new springs, OEM tend to be better. In fact, you might try OEM KTM springs, as they have a swivel hook at each end, and don't cause the spring to twist(prematurely breaking it). Good luck!

TaxPhd said:

Shoule I use OEM springs or something different?

Thanks!



Scott

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I'd stick w/the OEM springs, i tried a new set of fmf springs and lost them both w/in 15 minutes of riding.. Luckily i still had my OEM's
RIck

the same happened to mine i just welded it i didnt take the coating off,it welded up real nice

There is a brass gasket (p/n# 11060-1689) that goes in between the head and the pipe that you should replace. Check the pipe o-rings for nicks, or to see if the roundness has worn down. The best bet is to replace the o-rings; I would think that OEM o-rings (p/n# 671E2550) would work.

You should also loosen all of the pipe and muffler mounts and wiggle around the pipe and muffler with header springs attached and o-rings greased to make sure the header is seated flush, as some times a torsion is caused by the muffler stinger junction. The rubber boot where the pipe and the muffler meet might be glued or pipe clamped, not allowing this boot to rotate to relieve the torsion between the pipe and muffler. Re-tighten the front pipe mounts first, working back to the muffler. This same torsion could have caused your pipe mount to crack in the first place. Check the rubber on the pipe mounts to make sure that they have not been torn.

A KX250 should not leak, unless something is wrong.

I would guess that the OEM o-rings will be about $3.50 apiece. You can buy the FMF spring and o-ring kit for about $9.95, if you do an internet search. They are 50mm in diameter, but I don't know the width.

You may want to just order a top end gasket kit. It will come with the o-rings and many other gaskets that you'll eventually need. It's not much more than the o-rings themselves.

Jeremy