\: mufler swap

[snowcrash007]

I will be removing the current supertrapp and putting a stock muffler on my klr. I got the mounting bolts and new gasket. The PO did the change so its my first time doing this work. Are there any tips or tricks...or is it a straightforward loosen clamp, remove, put new gasket in and put the clamp back on? Thanks Crash

[Fred Hink]

It s a pretty straight forward job. Most of the time the existing exhaust gasket has been tightened into the head and looks like it might not be there. You will need a pick or a small screwdriver to get your old gasket out. I use a small dab of grease to hold the new gasket in place while tightening the bolts. The new exhaust gasket will have a flat side and a rounded side when new. I would put the flat side towards the head and the rounded side towards the header pipe. You may also want to use a little anti-seize on the mounting hardware. Fred http://www.arrowheadmotorsports.com From: snowcrash007 Sent: Monday, June 25, 2012 2:10 PM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] muffler swap question I will be removing the current supertrapp and putting a stock muffler on my klr. I got the mounting bolts and new gasket. The PO did the change so its my first time doing this work. Are there any tips or tricks...or is it a straightforward loosen clamp, remove, put new gasket in and put the clamp back on? Thanks Crash [Non-text portions of this message have been removed]

[Jeff Saline]

On Mon, 25 Jun 2012 20:10:53 -0000 "snowcrash007" writes:

> I will be removing the current supertrapp and putting a stock muffler > on my klr. I got the mounting bolts and new gasket. The PO did the > change so its my first time doing this work. Are there any tips or > tricks...or is it a straightforward loosen clamp, remove, put new > gasket in and put the clamp back on? > > Thanks > > Crash

<><><><><> <><><><><> Crash, It's pretty straight forward. Might want to use some anti-seize on the fasteners for the clamps, heat shields, clean out plugs. Check the fasteners after a couple of heat/cool cycles and then again after maybe 500 smiles. There was a recall a few years ago as mufflers were falling off within a few thousand miles or so. Happened to my nephew in CA. Just checking fasteners a few times usually removes the issue. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . ____________________________________________________________ 53 Year Old Mom Looks 33 The Stunning Results of Her Wrinkle Trick Has Botox Doctors Worried http://thirdpartyoffers.juno.com/TGL3141/4fe8cd4142981aabaa4st02vuc

[RobertWichert]

My heat shield screws were "too long" from the factory and the heat shield rattled. I ground down some Allen Heads to hold it tight. That may not have been what Kawa intended, but it stopped the rattle. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 6/25/2012 1:42 PM, Fred Hink wrote: > > It s a pretty straight forward job. Most of the time the existing > exhaust gasket has been tightened into the head and looks like it > might not be there. You will need a pick or a small screwdriver to get > your old gasket out. I use a small dab of grease to hold the new > gasket in place while tightening the bolts. The new exhaust gasket > will have a flat side and a rounded side when new. I would put the > flat side towards the head and the rounded side towards the header > pipe. You may also want to use a little anti-seize on the mounting > hardware. > > Fred > http://www.arrowheadmotorsports.com > > From: snowcrash007 > Sent: Monday, June 25, 2012 2:10 PM > To: DSN_KLR650@yahoogroups.com > Subject: [DSN_KLR650] muffler swap question > > I will be removing the current supertrapp and putting a stock muffler > on my klr. I got the mounting bolts and new gasket. The PO did the > change so its my first time doing this work. Are there any tips or > tricks...or is it a straightforward loosen clamp, remove, put new > gasket in and put the clamp back on? > > Thanks > > Crash > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

[Peter Dore]

I have an 08 KLR and I was told by the Harley Dealer that I bought it from that the PO upgraded the muffler and I think he said something about re-boring to 655 to match the muffler. I would like to go back to stock I think, the muffler on there is fairly loud, not as loud as the dirt bikes I hear riding up and down my street (illegally) but I think I would like it to be as quite as possible for when I am riding out in Nature (taking my cues from the Big Dog website). I am sorry to say I don't know hardly anything mechanical, and don't know what or why it would have been re-bored for a muffler, but I am wondering does that mean that now I cannot go back? Has something been made larger so that I would suffer power loss with the stock or maybe an even quieter muffler? Thanks for any help, Peter [Non-text portions of this message have been removed]

[Jeff Khoury]

If the PO did it properly, the jetting of the carburetor was changed to match the profile of the intake and exhaust. If you describe to us what kind of muffler and any intake modifications that were done, we can give you an idea of what you're going to need to do. If you simply swap a stock muffler back on you may end up running too rich which can give you problems starting the bike when hot or problems at higher altitudes. I have an extra stock muffler (very quiet) that I would let go for a reasonable price, if you're in the Southern California area. Shipping it would be expensive, as the thing weighs a *%&^ing ton. -Jeff Khoury

----- Original Message ----- From: "Peter Dore" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Tuesday, June 26, 2012 8:09:25 AM Subject: [DSN_KLR650] Re: muffler swap question I have an 08 KLR and I was told by the Harley Dealer that I bought it from that the PO upgraded the muffler and I think he said something about re-boring to 655 to match the muffler. I would like to go back to stock I think, the muffler on there is fairly loud, not as loud as the dirt bikes I hear riding up and down my street (illegally) but I think I would like it to be as quite as possible for when I am riding out in Nature (taking my cues from the Big Dog website). I am sorry to say I don't know hardly anything mechanical, and don't know what or why it would have been re-bored for a muffler, but I am wondering does that mean that now I cannot go back? Has something been made larger so that I would suffer power loss with the stock or maybe an even quieter muffler? Thanks for any help, Peter [Non-text portions of this message have been removed]

[RobertWichert]

Well, reboring to 655 isn't much reboring. Maybe an overbore for a repair. I would doubt very much if the muffler pipe connection was rebored to 655 anything! So I'd say to ignore everything that dealer told you. Not kidding. You should be able to go back to stock without any problem. The biggest problem may be finding the stock muffler to use. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 6/26/2012 8:09 AM, Peter Dore wrote: > > I have an 08 KLR and I was told by the Harley Dealer that I bought it > from that the PO upgraded the muffler and I think he said something > about re-boring to 655 to match the muffler. I would like to go back > to stock I think, the muffler on there is fairly loud, not as loud as > the dirt bikes I hear riding up and down my street (illegally) but I > think I would like it to be as quite as possible for when I am riding > out in Nature (taking my cues from the Big Dog website). > > I am sorry to say I don't know hardly anything mechanical, and don't > know what or why it would have been re-bored for a muffler, but I am > wondering does that mean that now I cannot go back? Has something been > made larger so that I would suffer power loss with the stock or maybe > an even quieter muffler? > > Thanks for any help, > > Peter > > [Non-text portions of this message have been removed] > > [Non-text portions of this message have been removed]

[Jeff Khoury]

Further information: There are several overbore kits for the KLR, and none of them REQUIRE exhaust modifications, but for maximum performance they are recommended. There are 658, 685, 688 and 705 kits (and may be others). Sometimes people do these for performance and some do them to solve oil burning issues that were common on early '08 bikes. You can still go back to the stock muffler, we just need to make sure your jetting is right. -Jeff Khoury

----- Original Message ----- From: "Jeff Khoury" To: "Peter Dore" Cc: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Tuesday, June 26, 2012 8:18:59 AM Subject: Re: [DSN_KLR650] Re: muffler swap question If the PO did it properly, the jetting of the carburetor was changed to match the profile of the intake and exhaust. If you describe to us what kind of muffler and any intake modifications that were done, we can give you an idea of what you're going to need to do. If you simply swap a stock muffler back on you may end up running too rich which can give you problems starting the bike when hot or problems at higher altitudes. I have an extra stock muffler (very quiet) that I would let go for a reasonable price, if you're in the Southern California area. Shipping it would be expensive, as the thing weighs a *%&^ing ton. -Jeff Khoury ----- Original Message ----- From: "Peter Dore" < pmdore@... > To: "DSN KLR650" < DSN_KLR650@yahoogroups.com > Sent: Tuesday, June 26, 2012 8:09:25 AM Subject: [DSN_KLR650] Re: muffler swap question I have an 08 KLR and I was told by the Harley Dealer that I bought it from that the PO upgraded the muffler and I think he said something about re-boring to 655 to match the muffler. I would like to go back to stock I think, the muffler on there is fairly loud, not as loud as the dirt bikes I hear riding up and down my street (illegally) but I think I would like it to be as quite as possible for when I am riding out in Nature (taking my cues from the Big Dog website). I am sorry to say I don't know hardly anything mechanical, and don't know what or why it would have been re-bored for a muffler, but I am wondering does that mean that now I cannot go back? Has something been made larger so that I would suffer power loss with the stock or maybe an even quieter muffler? Thanks for any help, Peter [Non-text portions of this message have been removed]

[Peter Dore]

The dealer (Harley dealer remember) didn't know much, they got the bike in, cleaned it up, put it on craigslist and I was there in their shop 50 minutes from my house before the bike was even dry from its cleaning (seriously it was still on the lift dripping dry). I wanted an 08 KLR and the previous two to pop up in my area were sold in less than 2 hours. I will listen to you guys way before that dealer. I do have a Kawasaki dealer near my house, one of those power sports places that sells Kawasaki, Susuki, lots of 4-wheeler things and CanAms. I hope they will know what they are doing, they didn't know what I was talking about when I asked about the "doo-hickey" . I am not mechanically inclined, but I will try to figure out what kind of muffler it is tonight when I get home to look at it and get back to the group. I am in the St. Louis , MO area, and will welcome any mechanical advice or help anyone ever wants to give, and always open to go on rides when I can make it. Thanks, Peter From: RobertWichert [mailto:robert@...] Sent: Tuesday, June 26, 2012 10:26 AM To: Peter Dore Cc: DSN_KLR650@yahoogroups.com Subject: Re: [DSN_KLR650] Re: muffler swap question Well, reboring to 655 isn't much reboring. Maybe an overbore for a repair. I would doubt very much if the muffler pipe connection was rebored to 655 anything! So I'd say to ignore everything that dealer told you. Not kidding. You should be able to go back to stock without any problem. The biggest problem may be finding the stock muffler to use. Robert Wichert P.Eng. LEED AP BD&C +1 916 966 9060 FAX +1 916 966 9068 ===============================================

On 6/26/2012 8:09 AM, Peter Dore wrote: I have an 08 KLR and I was told by the Harley Dealer that I bought it from that the PO upgraded the muffler and I think he said something about re-boring to 655 to match the muffler. I would like to go back to stock I think, the muffler on there is fairly loud, not as loud as the dirt bikes I hear riding up and down my street (illegally) but I think I would like it to be as quite as possible for when I am riding out in Nature (taking my cues from the Big Dog website). I am sorry to say I don't know hardly anything mechanical, and don't know what or why it would have been re-bored for a muffler, but I am wondering does that mean that now I cannot go back? Has something been made larger so that I would suffer power loss with the stock or maybe an even quieter muffler? Thanks for any help, Peter [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[Jud]

Peter, You will be in better hands here than you will with just about any dealer. Best of all, the advice you get here is free, and untainted by any profit motive. That is not to say that Fred won't be glad to sell you something, but he gives straight advice, and he knows what he is talking about, unlike the shuck and jive you will get from a lot of places. The balancer idler adjuster quadrant (doohickey) is not a matter of any urgency on the '08 and later bikes. It is worth changing at some point so that you can continue to adjust your balancer chain, but we have never heard of one breaking, unlike the earlier ones.

--- In DSN_KLR650@yahoogroups.com, Peter Dore wrote: > > The dealer (Harley dealer remember) didn't know much, they got the bike in, cleaned it up, put it on craigslist and I was there in their shop 50 minutes from my house before the bike was even dry from its cleaning (seriously it was still on the lift dripping dry). I wanted an 08 KLR and the previous two to pop up in my area were sold in less than 2 hours. > > I will listen to you guys way before that dealer. I do have a Kawasaki dealer near my house, one of those power sports places that sells Kawasaki, Susuki, lots of 4-wheeler things and CanAms. I hope they will know what they are doing, they didn't know what I was talking about when I asked about the "doo-hickey" . > > I am not mechanically inclined, but I will try to figure out what kind of muffler it is tonight when I get home to look at it and get back to the group. I am in the St. Louis , MO area, and will welcome any mechanical advice or help anyone ever wants to give, and always open to go on rides when I can make it. > > Thanks, > > Peter > > > > From: RobertWichert [mailto:robert@...] > Sent: Tuesday, June 26, 2012 10:26 AM > To: Peter Dore > Cc: DSN_KLR650@yahoogroups.com > Subject: Re: [DSN_KLR650] Re: muffler swap question > > Well, reboring to 655 isn't much reboring. Maybe an overbore for a repair. I would doubt very much if the muffler pipe connection was rebored to 655 anything! So I'd say to ignore everything that dealer told you. Not kidding. > > You should be able to go back to stock without any problem. The biggest problem may be finding the stock muffler to use. > > > > > Robert Wichert P.Eng. LEED AP BD&C > > +1 916 966 9060 > > FAX +1 916 966 9068 > > > > > > > > > > > > > > > > =============================================== > On 6/26/2012 8:09 AM, Peter Dore wrote: > > > I have an 08 KLR and I was told by the Harley Dealer that I bought it from that the PO upgraded the muffler and I think he said something about re-boring to 655 to match the muffler. I would like to go back to stock I think, the muffler on there is fairly loud, not as loud as the dirt bikes I hear riding up and down my street (illegally) but I think I would like it to be as quite as possible for when I am riding out in Nature (taking my cues from the Big Dog website). > > I am sorry to say I don't know hardly anything mechanical, and don't know what or why it would have been re-bored for a muffler, but I am wondering does that mean that now I cannot go back? Has something been made larger so that I would suffer power loss with the stock or maybe an even quieter muffler? > > Thanks for any help, > > Peter > > [Non-text portions of this message have been removed] > > > > > [Non-text portions of this message have been removed] >