Slip on Big Gun muffler - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 4 Old 03-10-2007, 02:13 AM Thread Starter
Join Date: Mar 2007
Posts: 11
Slip on Big Gun muffler

I purchased a Big Gun Evo X slip on muffler for my 2006 KLR650.
Is it really just slip on or should I use something to seal the 2 pipes together?
I saved about $150-200 by just buying the muffler and not the header pipe as well.
I bought some metallic foil exhaust tape that could be used where the 2 pipes come together.

Also, has anyone else installed a Big Gun and did they have to rejet?
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post #2 of 4 Old 03-12-2007, 06:34 PM
1st Gear
Join Date: Jan 2007
Location: Santa Rosa, CA
Posts: 19

I have a Big Gun Quiet Series with the header pipe. I also installed a K & N filter. With that set up the bike ran way to lean. I had to install a dynojet kit. I used the 150 jet, set the e-clip on the needle at the 3rd notch from the top. I drilled the slide for the stage 2 setup and backed out the idle adjustment 2.75 turns. Bike runs very strong and pulls hard all the way to 7000 RPM. I don't usually shift that high, but I wanted to see how hard the bike would pull. So, now I know I can rev that high if I have to and it won't fall on its face.

There are only two kinds of motorcycles: those we need and those we want!
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post #3 of 4 Old 03-15-2007, 09:04 PM Thread Starter
Join Date: Mar 2007
Posts: 11
After 6 months of the exhaust just sitting next to the bike, I finally put it on and was able to fire up the bike.
Of course it doesn't run properly because 6 months ago I didn't prep the bike for it's unplanned storage.
I am ordering a rejet kit from Dual Star with the hopes that once I get the kit, removal, cleaning, rejetting and replacement should be fairly easy. OH YEA, I CAN'T WAIT!!!!(sarcasm)
Well at least I'll have a bike that actually runs better. California bikes are jetted so lean that once you get it above 4000 feet the bike will still go forward but faster when pointed downhill.

Any tips, hints or tricks for cleaning and rejetting a carb would be greatly apreciated.
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post #4 of 4 Old 05-04-2007, 05:52 AM Thread Starter
Join Date: Mar 2007
Posts: 11
Rejet of carb complete and works great.
150 needle and idle to 3.5 turns.
I will check to see if to rich or lean in 500 mi.
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