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Help ZR250 Exhaust Change

Discussion in 'Kawasaki 250cc In-line 4's' started by Peter Batt, Oct 6, 2016.

  1. Peter Batt

    Peter Batt Active Member

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    Hey guys,

    Just went to the mechanic to get the blue slip for my 1999 ZR250 Balius and stumbled upon something
    Everything was fine with the bike EXCEPT the aftermarket exhaust that I bought the bike with
    The guy in the shop said I have to either get the label for the exhaust (Neither I nor the previous seller know what it is) or buy an exhaust that is labelled
    As you can see in the picture, a flange is used to connect the muffler to the main tubes, so I can't use an OEM muffler as it is a different connection.

    What would be the best way to get around this?
    1. Try find the model and contact a supplier for a tag (no idea where to start)
    2. Try find my exact bike at a wrecker (browsed many wreckers and haven't found one)
    3. Spend $500ish on the stock exhaust (really dont want to do this)
    4. Buy another, legal exhaust and try to work out how to attach it
    5. Pls help

    Thanks :D

    $_20.JPG
     
  2. Peter Batt

    Peter Batt Active Member

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  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  4. Peter Batt

    Peter Batt Active Member

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    Oh sweet I didn't even know this was a thing, lets hope they come back with something.
    Thanks! :)
     
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  5. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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  6. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  7. kiffsta

    kiffsta Senior Member

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    hey Peter

    from memory the stock ZR250 exhaust was all one piece, it looks like your has been cut and some form of adapter welded on.

    Stock ZR pipe
    zr250.jpg

    Measure the bolt holes on the adapter plate and post them up. I have a stock ZXr250 pipe and a CBR250 pipe, once of those might fit

    Kiff
     
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  8. Peter Batt

    Peter Batt Active Member

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  9. Peter Batt

    Peter Batt Active Member

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    Hi Kiff,
    The bolt holes are about 83mm from each other, center to center.
    The tube is about 55mm outside diameter and 50mm inside.
    I'll post pics as to what im looking at, thanks for the help!

    Edit: pics are playing up a bit
     

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  10. kiffsta

    kiffsta Senior Member

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    Thats a custom bracket, sorry i dont have anything that will bolt on
     
  11. Peter Batt

    Peter Batt Active Member

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    You reckon its fully custom??
    Do you know what my other options are in regards to getting the blue slip without knowing the model of the exhaust?
    Thanks
     
  12. kiffsta

    kiffsta Senior Member

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    The adapter they have welded on is weird, I'm not sure you will find anything that bolts straight on.

    Maybe call a couple of exhaust shops in Sydney and see what they say about testing your system and certifying it with a badge, the problem you are going to have is that the exhaust can you have fitted will be a straight through system which will most likely fail the test, factory pipes are tri flow which are much quieter.

    See how you go on Findapart, finding a stock exhaust will be the path of least resistance
     
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  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    If using findapart ask for 'headers and muffler' complete so you get the original 1 piece setup.
     
  14. Peter Batt

    Peter Batt Active Member

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    Yeah my uncle knows some guys that can get it certified, if its way too loud for legal standards then ill do my best to get the stock headers/muffler
    Thanks for the help :)
     
  15. Joker

    Joker See "about me" for contact details. Contributing Member

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    The guy is being anal in relation to ADR 83/00 (https://www.legislation.gov.au/Details/F2009C01270) most likely where he basically wants proof your exhaust has been tested and is certified to the ADR requirements.

    Get it tested and certified, nothing wrong with an aftermarket exhaust provided it complies to the regulations under the ADR's.
     
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  16. Peter Batt

    Peter Batt Active Member

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    Yeahh, I'll see what the bike mechanic offers, hopefully he'll be able to rev it to 6000rpm's and record the db and it'll be easy.
    If its over the db limit though I'll probably have to buy an OEM one for the test
    Thanks
     
  17. tarmacsurfer

    tarmacsurfer Well-Known Member

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    Wow they seem hot on this in Oz?
    Vast majority of UK testers don't give a sh#t about loud aftermarket exhausts.
     
  18. Peter Batt

    Peter Batt Active Member

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    Yeah the bike guy said he used to let it slide but the roads services caught him and got suspended from doing it for a while
     
  19. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    shame that, he was probably the go to guy previously, on the upside if you ever get hassled by the fuzz they can't issue a defect for the exhaust just to annoy you
     

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