front brakes/rotor

[idaho_mtgoat]

A co-worker just got a 09 KLR. He immediately added some enhancements (some at my suggestion). One that I had not heard of was to drive a dowel in his exhaust and using a hole saw remove the end of his exhaust. He said it gave him "alot" of added power after he adjusted the carb. I inquired of others and was told that drill a couple of holes in the end of the exhaust will do the same. What are my options as I am a bit of a minimalist and cutting the end out of my exhaust seems a bit radical. He was also ordering a end to cover the hole. Where can I find a cover to "hide" my modifications if they are worth performing? What should I watch out for, are they legal etc etc. Thanks Pat '07 KLR (red, fast fading to pink)

[Jeff Khoury]

I did the aforementioned exhaust mod and found it to increase the flow and improve the tone of the exhaust. It's not a whole lot louder, but definitely deeper. To my calibrated ear, it's still under the 93db limit. The police don't even look twice at me when I'm riding it. The bike feels "snappier" than it did before, and of course you'll want to do the $0.22 carb mod at the same time to keep the mixture right with the increased flow. I used a dowel around the drill bit to keep a 2" hole saw centered and cut out a nice big hole in the rear. If you do it just right, tweety will come out in one easy piece. Then I went down and bought a chrome exhaust tip at Pep Boys and had it welded in the hole, then sanded and painted with barbecue paint. Don't go any larger than 2". The internal size of the perforated screen and packing is 2" and you run the risk of chewing it up, and you don't gain any benefit by doing so. -Jeff Khoury Astatic Solutions, LLC.

----- Original Message ----- From: "idaho_mtgoat" To: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Wednesday, June 17, 2009 4:19:30 AM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Exhaust Modifications A co-worker just got a 09 KLR. He immediately added some enhancements (some at my suggestion). One that I had not heard of was to drive a dowel in his exhaust and using a hole saw remove the end of his exhaust. He said it gave him "alot" of added power after he adjusted the carb. I inquired of others and was told that drill a couple of holes in the end of the exhaust will do the same. What are my options as I am a bit of a minimalist and cutting the end out of my exhaust seems a bit radical. He was also ordering a end to cover the hole. Where can I find a cover to "hide" my modifications if they are worth performing? What should I watch out for, are they legal etc etc. Thanks Pat '07 KLR (red, fast fading to pink) [Non-text portions of this message have been removed]

[Rick McCauley]

What is this muffler mod. Are there pictures? What is the 22 carb mod. Rick A17

--- On Wed, 6/17/09, Jeff Khoury wrote: From: Jeff Khoury Subject: Re: [DSN_KLR650] Exhaust Modifications To: "idaho_mtgoat" Cc: "DSN KLR650" DSN_KLR650@yahoogroups.com> Date: Wednesday, June 17, 2009, 11:47 AM I did the aforementioned exhaust mod and found it to increase the flow and improve the tone of the exhaust. It's not a whole lot louder, but definitely deeper. To my calibrated ear, it's still under the 93db limit. The police don't even look twice at me when I'm riding it. The bike feels "snappier" than it did before, and of course you'll want to do the $0.22 carb mod at the same time to keep the mixture right with the increased flow. I used a dowel around the drill bit to keep a 2" hole saw centered and cut out a nice big hole in the rear. If you do it just right, tweety will come out in one easy piece. Then I went down and bought a chrome exhaust tip at Pep Boys and had it welded in the hole, then sanded and painted with barbecue paint. Don't go any larger than 2". The internal size of the perforated screen and packing is 2" and you run the risk of chewing it up, and you don't gain any benefit by doing so. -Jeff Khoury Astatic Solutions, LLC. ----- Original Message ----- From: "idaho_mtgoat" To: "DSN KLR650" Sent: Wednesday, June 17, 2009 4:19:30 AM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Exhaust Modifications A co-worker just got a 09 KLR. He immediately added some enhancements (some at my suggestion). One that I had not heard of was to drive a dowel in his exhaust and using a hole saw remove the end of his exhaust. He said it gave him "alot" of added power after he adjusted the carb. I inquired of others and was told that drill a couple of holes in the end of the exhaust will do the same. What are my options as I am a bit of a minimalist and cutting the end out of my exhaust seems a bit radical. He was also ordering a end to cover the hole. Where can I find a cover to "hide" my modifications if they are worth performing? What should I watch out for, are they legal etc etc. Thanks Pat '07 KLR (red, fast fading to pink) [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[Jeff Khoury]

Hi, Here is the guide I used in doing the 22 cent mod. I got the #4 brass washers from B&B hardware in Culver City. It's definitely worth the time and 22 cents. (actually the washers cost me 18 cents and a couple of bucks for the right sized drill bit) http://www.klr650.net/forums/showthread.php?t=41112 All I can give you on the muffler mod is the description I previously posted, since I didn't take pictures during the process. I'll take some pictures of the completed project when I get home and post them. -Jeff Khoury Astatic Solutions, LLC.

----- Original Message ----- From: "Rick McCauley" To: "dsn klr650" dsn_klr650@yahoogroups.com> Sent: Wednesday, June 17, 2009 2:18:47 PM GMT -08:00 US/Canada Pacific Subject: Re: [DSN_KLR650] Exhaust Modifications What is this muffler mod. Are there pictures? What is the 22 carb mod. Rick A17 --- On Wed, 6/17/09, Jeff Khoury < jeff@... > wrote: From: Jeff Khoury < jeff@... > Subject: Re: [DSN_KLR650] Exhaust Modifications To: "idaho_mtgoat" < patncindy@... > Cc: "DSN KLR650" < DSN_KLR650@yahoogroups.com > Date: Wednesday, June 17, 2009, 11:47 AM I did the aforementioned exhaust mod and found it to increase the flow and improve the tone of the exhaust. It's not a whole lot louder, but definitely deeper. To my calibrated ear, it's still under the 93db limit. The police don't even look twice at me when I'm riding it. The bike feels "snappier" than it did before, and of course you'll want to do the $0.22 carb mod at the same time to keep the mixture right with the increased flow. I used a dowel around the drill bit to keep a 2" hole saw centered and cut out a nice big hole in the rear. If you do it just right, tweety will come out in one easy piece. Then I went down and bought a chrome exhaust tip at Pep Boys and had it welded in the hole, then sanded and painted with barbecue paint. Don't go any larger than 2". The internal size of the perforated screen and packing is 2" and you run the risk of chewing it up, and you don't gain any benefit by doing so. -Jeff Khoury Astatic Solutions, LLC. ----- Original Message ----- From: "idaho_mtgoat" To: "DSN KLR650" Sent: Wednesday, June 17, 2009 4:19:30 AM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Exhaust Modifications A co-worker just got a 09 KLR. He immediately added some enhancements (some at my suggestion). One that I had not heard of was to drive a dowel in his exhaust and using a hole saw remove the end of his exhaust. He said it gave him "alot" of added power after he adjusted the carb. I inquired of others and was told that drill a couple of holes in the end of the exhaust will do the same. What are my options as I am a bit of a minimalist and cutting the end out of my exhaust seems a bit radical. He was also ordering a end to cover the hole. Where can I find a cover to "hide" my modifications if they are worth performing? What should I watch out for, are they legal etc etc. Thanks Pat '07 KLR (red, fast fading to pink) [Non-text portions of this message have been removed] [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[Jeff Khoury]

How I did the muffler mod (a.k.a. tweetyectomy) What you need: 2" metal hole saw 4" of 1" diameter dowel a drill bit of the appropriate size for the hole saw a pair of needle nosed pliers a GOOD drill a 1 7/8" or 2" OD piece of exhaust pipe or exhaust tip a hacksaw sandpaper hi-temp matte black barbecue paint a magnet on a stick (optional) A few bucks to pay a welder. * Chuck the drill bit and drill a longitudinal hole in the dowel. (The dowel will serve as a guide to keep the hole saw centered while cutting the back of your muffler.) * Unchuck the drill bit and chuck in the hole saw. * Attach the drill bit to the hole saw and tighten. * Slip the dowel over the drill bit. * Slide the whole contraption into the opening of your exhaust. * Cut the hole starting with slow speed and slow feed until you get a groove that the hole saw will ride in. Use cutting oil or similar applied at intervals while you're cutting. * Once the groove is created, you can increase the speed of the drill. * When you're getting close to breaking through, be careful not to push too hard and ram the hole saw into the guts of the muffler. * Tweety should come out easily if you grasp it with the needle nose pliers. * Use the magnet to pick up any shavings that fell into the muffler. * Stick the exhaust tip into the hole and guesstimate how much you want to cut off to leave the desired amount protruding. * Cut the exhaust tip to length with the hacksaw. * Have someone weld it in for you. (Midas did it for me for 20 bucks) * Surface sand all exposed metal to allow for best paint adhesion * Rattle-can the bare metal parts. * Start and listen to your new better-sounding, freer-flowing exhaust. What is this muffler mod. Are there pictures? What is the 22 carb mod. Rick A17

--- On Wed, 6/17/09, Jeff Khoury < jeff@... > wrote: From: Jeff Khoury < jeff@... > Subject: Re: [DSN_KLR650] Exhaust Modifications To: "idaho_mtgoat" < patncindy@... > Cc: "DSN KLR650" < DSN_KLR650@yahoogroups.com > Date: Wednesday, June 17, 2009, 11:47 AM I did the aforementioned exhaust mod and found it to increase the flow and improve the tone of the exhaust. It's not a whole lot louder, but definitely deeper. To my calibrated ear, it's still under the 93db limit. The police don't even look twice at me when I'm riding it. The bike feels "snappier" than it did before, and of course you'll want to do the $0.22 carb mod at the same time to keep the mixture right with the increased flow. I used a dowel around the drill bit to keep a 2" hole saw centered and cut out a nice big hole in the rear. If you do it just right, tweety will come out in one easy piece. Then I went down and bought a chrome exhaust tip at Pep Boys and had it welded in the hole, then sanded and painted with barbecue paint. Don't go any larger than 2". The internal size of the perforated screen and packing is 2" and you run the risk of chewing it up, and you don't gain any benefit by doing so. -Jeff Khoury Astatic Solutions, LLC. ----- Original Message ----- From: "idaho_mtgoat" To: "DSN KLR650" Sent: Wednesday, June 17, 2009 4:19:30 AM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Exhaust Modifications A co-worker just got a 09 KLR. He immediately added some enhancements (some at my suggestion). One that I had not heard of was to drive a dowel in his exhaust and using a hole saw remove the end of his exhaust. He said it gave him "alot" of added power after he adjusted the carb. I inquired of others and was told that drill a couple of holes in the end of the exhaust will do the same. What are my options as I am a bit of a minimalist and cutting the end out of my exhaust seems a bit radical. He was also ordering a end to cover the hole. Where can I find a cover to "hide" my modifications if they are worth performing? What should I watch out for, are they legal etc etc. Thanks Pat '07 KLR (red, fast fading to pink) [Non-text portions of this message have been removed] [Non-text portions of this message have been removed] [Non-text portions of this message have been removed]

[Jeff Khoury]

----- Original Message ----- From: "E Hines" < ridingmyklr@... > To: "Jeff Khoury" < jeff@... > Sent: Thursday , June 18, 2009 5:37:40 AM GMT -08:00 US/Canada Pacific Subject: Re: [DSN_KLR650] Exhaust Modifications Does this destory the spark arrestor? I would think it would. I ride off road as often as possible and have had some of my friends exhausts checked........ OK... First let me start by saying that this is my opinion only. No, I don't think it affects the spark arresting feature of the muffler, for a few reasons. First, the tweety is simply a tube, solid on the outside, perforated on the inside with packing in between. It extends into the muffler and sits inside a larger version of the same thing. Second, the KLR muffler is a dual-chamber design, and I believe the spark arresting feature lies between the two chambers. Third, when you've cut tweety out, you can see into the muffler. As you look into the muffler, you see a concave piece of metal with radial fins sticking out to the side that covers the inlet to the second chamber from the first. I believe this is the spark arrestor. BUT, here is the kicker: Most spark arrestors are simply brass screens that cover the exhaust flow one way or another. The USFS typically tests these by inserting a dowel into your exhaust pipe and feeling for a screen to stop the dowel. The KLR exhaust would fail this test even though it's a USFS approved muffler, because tweety is just a tube, and the dowel would go all the way to the back of the second chamber where it would hit that concave metal thingy. This mod does not change the design at all, it simply makes the exit pipe larger (4 times the size - .78sq.in. to 3.14sq.in.) I've only been questioned on my KLR exhaust once, when entering the San Gabriel River OHV area. I showed him the exhaust and the USFS stamp on the side and he let me in with no further questions. The funny thing is that he didn't even look at my brother's YZ250 with an FMF PowerCore. However, I have heard accounts of them testing with the dowel method and it depends on the officer whether or not it would be an issue. You'd have to explain the USFS stamp and the dual-chamber design and they'd PROBABLY be OK with it. I've also considered taking a slightly larger exhaust tip, cutting it short then drilling and tapping some screw holes near the back for set screws. I would then cover the exit pipe with brass screen and slide the larger tip over and tighten, giving a definite, visible barrier. Others' opinions may be different. -Jeff Khoury [Non-text portions of this message have been removed]

[Jeff Saline]

Guys, The link below might be of some interest about exhaust noise and spark arrestors. My guess is any modification to the KLR exhaust system voids the USFS approval. I prefer to ride only with folks with fairly quiet exhaust systems that have "real" spark arrestors. I don't mind telling someone I won't ride with them because of their exhaust or riding habits they have that I don't like. I don't want to be or encourage problems. 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, 79 R100RT http://www.quietbike.org/Noise_Presentation_Supplement_7_03.pdf Society of Automotive Engineers (SAE) Recommended Practice SAE J350, "Requirements of Single Position Application General Purpose Arresters Society of Automotive Engineers (SAE) Recommended Practice SAE J335b, "Multi-Positioned Small Engine Exhaust Fire Ignition Suppression." Requirements to obtain the SAE J335b specifications are as follows: (i) The spark arrester shall be designed to retain or destroy ninety percent of the carbon particles having a major diameter greater than 0.023 inches (0.584mm). (ii) The exhaust system shall be designed so that the exposed surface temperature shall not exceed five hundred fifty degrees Fahrenheit (288 degrees Centigrade) where it may come in direct contact with forest fuels. (iii) The exhaust system shall be designed so that the exhaust gas temperature shall not exceed four hundred seventy-five degrees Fahrenheit (246 degrees Centigrade) where the exhaust flow may strike forest fuels. (iv) The exhaust system shall be designed in such a manner that there are no pockets or corners where flammable material might accumulate. Pockets are permissible only if it can be substantiated by suitable test that material can be prevented from accumulating in the pockets. (v) The exhaust system must be constructed of durable material and so designed that it will, with normal use and maintenance, provide a reasonable service life. Parts designed for easy replacement as a part of routine maintenance shall have a service life of not less than fifty hours. Cleaning of parts shall not be required more frequently than once for each eight hours of operation. The spark arrester shall be so designed that it may be readily inspected and cleaned. SNIP ... ____________________________________________________________ You can take it with you! Click here for a luxurious new motor home and travel in style! http://thirdpartyoffers.juno.com/TGL2141/fc/BLSrjpTD0fgwHspNj0YhVHv8b8vDLy6RQbHHCESttoI3S2oHlo7RE9dbviw/ [Non-text portions of this message have been removed]

[Jeff Khoury]

I understand completely and I don't like extremely loud exhausts either. This mod, while it is a little louder, I'm sure it's still under 93db and the police don't even blink at me. The tone is significantly deeper, and the spark cone is still in place. (Just to clarify) -Jeff Khoury

----- Original Message ----- From: "Jeff Saline" To: jeff@..., ridingmyklr@... Cc: "DSN KLR650" DSN_KLR650@yahoogroups.com> Sent: Thursday, June 18, 2009 10:15:19 AM GMT -08:00 US/Canada Pacific Subject: Re: [DSN_KLR650] Exhaust Modifications Guys, The link below might be of some interest about exhaust noise and spark arrestors. My guess is any modification to the KLR exhaust system voids the USFS approval. I prefer to ride only with folks with fairly quiet exhaust systems that have "real" spark arrestors. I don't mind telling someone I won't ride with them because of their exhaust or riding habits they have that I don't like. I don't want to be or encourage problems. 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, 79 R100RT http://www.quietbike.org/Noise_Presentation_Supplement_7_03.pdf Society of Automotive Engineers (SAE) Recommended Practice SAE J350, "Requirements of Single Position Application General Purpose Arresters Society of Automotive Engineers (SAE) Recommended Practice SAE J335b, "Multi-Positioned Small Engine Exhaust Fire Ignition Suppression." Requirements to obtain the SAE J335b specifications are as follows: (i) The spark arrester shall be designed to retain or destroy ninety percent of the carbon particles having a major diameter greater than 0.023 inches (0.584mm). (ii) The exhaust system shall be designed so that the exposed surface temperature shall not exceed five hundred fifty degrees Fahrenheit (288 degrees Centigrade) where it may come in direct contact with forest fuels. (iii) The exhaust system shall be designed so that the exhaust gas temperature shall not exceed four hundred seventy-five degrees Fahrenheit (246 degrees Centigrade) where the exhaust flow may strike forest fuels. (iv) The exhaust system shall be designed in such a manner that there are no pockets or corners where flammable material might accumulate. Pockets are permissible only if it can be substantiated by suitable test that material can be prevented from accumulating in the pockets. (v) The exhaust system must be constructed of durable material and so designed that it will, with normal use and maintenance, provide a reasonable service life. Parts designed for easy replacement as a part of routine maintenance shall have a service life of not less than fifty hours. Cleaning of parts shall not be required more frequently than once for each eight hours of operation. The spark arrester shall be so designed that it may be readily inspected and cleaned. SNIP ... ____________________________________________________________ You can take it with you! Click here for a luxurious new motor home and travel in style! [Non-text portions of this message have been removed]

[Horton Oliphant]

Here are the original instructions for this mod: www.angelfire.com/planet/foxinsocks1947/tweetyfix.htm If done correctly it will not destroy the spark arrestor and only be very slightly louder. I doubt very much that it would make a noticeable difference in power. Alan Henderson A13 Iowa idaho_mtgoat wrote:

> > I inquired of others and was told that drill a couple of holes in the > end of the exhaust will do the same. What are my options as I am a > bit of a minimalist and cutting the end out of my exhaust seems a bit > radical. He was also ordering a end to cover the hole. Where can I > find a cover to "hide" my modifications if they are worth performing? > What should I watch out for, are they legal etc etc. > > Thanks Pat '07 KLR (red, fast fading to pink) > >

[Jud Jones]

--- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote:

> I don't mind telling someone I won't ride > with them because of their exhaust or riding habits they have that I > don't like.

This comment reminds me of an episode that occurred a few years ago during Rally Week. We were staying at Whispering Pines, and had gone out in a fairly large group (8 or 9 bikes) on a back-road/dualsport ride. Rob Himmelman was riding the Nada GS, an R60/5 with knobbies and a few dirt bike accoutrements, a legendary veteran of the Elephant Ride and the Battle of the Legends In Their Own Minds. There was a particularly annoying fellow along for the ride who kept tearing up and down the road on his borrowed XR200, doing doughnuts and skidding stops. At one point, we were swapping bikes, and this clown asked Rob if he could try out the NADA GS. Rob told him no. "Why won't you let me ride your bike?" "Because you ride like an a$$hole."