Question about 2004 kawasaki KX 250 F

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Why does my kx250f pipe get red hot to where it melts and the exhaust starts too pop so why does it do that?

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Several things are possible. The baffles inside the muffler may have partially collasped causing a restriction in the exhaust. The fuel / air mixture may be too lean. A lean mix burns hot. The stock main jet is a #178 (stamped on the jet). Try a richer jet, #180 or #182. Also, use only premium gas without ethanol. Be sure your gearbox oil is clean 10 w 40 motor oil. NO SYNTHETIC LUBRICANTS. Check the radiator coolant flow and temperature to be certain the engine is getting cooled as it runs. Be sure mud /trash is not blocking the radiator fins. Also check the spark plug. The stock plug is an NGK CR8EB. Replace it with a colder plug, NGK CR9EB

Posted on Aug 02, 2009

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Posted on Jan 02, 2017

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Hi, Anonymous and the usual suspects are:
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For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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https://www.kawasakiforums.com/forum/klx-250s-71/exhaust-header-glowing-red-hot-31298
https://www.howtomotorcyclerepair.com/images/Kawasaki-KX-125-KX250-Service-Manual-2003-2004-2005-2006-2007-2008.pdf
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4. Massive air leak.
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7. Wrong heat range spark plug.
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For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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6. Intake manifold seals have failed.
7. Wrong heat range spark plug.
8. Fuel delivery system running too lean.
9. Faulty Map, O2, MAF, TPS, sensors.
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For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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