Laser Pro Duro or other quiet exhaust - 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 25 Old 01-27-2014, 03:01 PM Thread Starter
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Laser Pro Duro or other quiet exhaust

I'm about ready to order a Laser Pro Duro muffler for the KLR. I think my stocker is rusting so it's running both slightly leaner and slightly louder.

It looks like the Laser Pro Duro is welded stainless with some baffles and some packing inside. If it cannot be repacked, what's the longevity like on this muffler?

What other exhausts would be as quiet or quieter than stock? Less weight would be fine. Repacking often is not so fine. I won't buy anything that will be loud.

The Laser Pro Duro is about $444 so I'll call that the budget for this.

ON THE OTHER HAND, I've built exhaust baffles for another bike and it was a pain but ended successfully. Tom Schmitz wrote about GSX mufflers on a KLR and info about sound testing here.

I COULD be convinced to work on it. But with other projects I won't work from scratch on this. I'd be able to build a resonator as input to some other muffler.

Thanks.
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post #2 of 25 Old 01-27-2014, 08:08 PM
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Quote:
Originally Posted by Grinnin View Post

...

What other exhausts would be as quiet or quieter than stock? Less weight would be fine. Repacking often is not so fine. I won't buy anything that will be loud.

The Laser Pro Duro is about $444 so I'll call that the budget for this.

....

Thanks.

I don't believe you'll find a muffler as quiet as the OEM. Lighter yes, quieter no.

Plenty of OEM mufflers on Ebay for <$100

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #3 of 25 Old 01-27-2014, 11:18 PM
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Originally Posted by Grinnin View Post
... GSX mufflers on a KLR ...
The latest deal is to use Hayabusa cans as the supply GSRX cans has pretty well dried up.

I'm still using a Gixxer can, but I've got a 'Busa can waiting.

MacG is the expert on using the 'Busa can.

T

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post #4 of 25 Old 01-28-2014, 06:24 AM
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The GSXR and Busa cans will be constructed similarly and sound similar. They will sound more "throaty" but not quiter than OEM. One advantage of these is they never need repacking.
Here's an idea of what the sound is on a KLR. It's a 40FO GSXR can with Titanium internals


www.youtube.com/watch?v=w4O5FNcV_R4&feature
If you wanted to make it quieter, a core could be made and installed that would probably ease the tone a bit yet still be light weight and durable.

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post #5 of 25 Old 01-28-2014, 06:46 AM Thread Starter
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Originally Posted by MacG View Post
TOne advantage of these is they never need repacking.
. . .

If you wanted to make it quieter, a core could be made and installed that would probably ease the tone a bit yet still be light weight and durable.
Good info. AND a good-sounding exhaust (though you're right I'm looking for quieter).

It looks like you angle yours down toward where the stock header exits. The stock can has an offset. Instead of a core, welding up a resonator with offset could work if the new can is short enough. I'd start to gain back weight though.

I really have too many projects; why do I start new ones?

THANKS.
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post #6 of 25 Old 01-28-2014, 08:54 AM
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I have pics on when I did the install and made the midpipe that will give a better idea of what it looks like under the plastic. I'll try to get them posted this evening.

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post #7 of 25 Old 01-28-2014, 10:21 AM Thread Starter
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That'd be great. Thanks.
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post #8 of 25 Old 01-28-2014, 05:34 PM
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Here’s how I ended up positioning the muffler so it would clear everything plus not hang too low.



A side view for reference



I made a bracket from ¼” thick aluminum that used two of the KLR mounting holes and bolted the muffler to the bracket. Also a view that gives an idea of how it sets near the frame. I didn’t really like the aluminum look on this bike so I painted the muffler and bracket with high temp paint.





Last edited by MacG; 01-28-2014 at 05:42 PM.
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post #9 of 25 Old 01-28-2014, 05:37 PM
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Here are some picks of the midpipe if you want to make one or get someone to make one.
I made the mid pipe out of 2” O.D. x .065 wall stainless tubing. By buying elbows of the same size and cutting to the needed angles. You can shape the pipe anyway you need to for clearance and alignment. An OEM pipe from the street bike can also sometimes be modified



I mounted the muffler first and then just routed the pipe to fit.



Last edited by MacG; 01-28-2014 at 05:42 PM.
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post #10 of 25 Old 01-28-2014, 05:39 PM
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I put four slits in the end of the midpipe to attach to the header pipe.




I put a ring inside to stop the OEM exhaust gasket from going too far in the pipe. The OEM clamp works fine to clamp the two pipes together.




I put a UFS approved spark arrestor in since the street bike muffler didn’t have one.




Last edited by MacG; 01-28-2014 at 05:43 PM.
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