Soft Exhaust Retainer -- factory feature or overheat abuse? - 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 2 Old 04-23-2014, 08:09 AM Thread Starter
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Join Date: Feb 2013
Location: Maine
Posts: 368
Question Soft Exhaust Retainer -- factory feature or overheat abuse?

Does the aluminum retainer for the head pipe soften or is it already soft?

Where the head pipe goes into the head of my 1st-gen KLR, there's an aluminum retainer with an oval hole and two bolt holes (er, stud holes).

Mine is soft and I tighten it gently but eventually it bends and the nuts bottom out. I can easily flatten it but the process just repeats. I cannot find any leaks up there but it's not what I'd consider "right".

I got a Boy Scout mess kit in about '65 and before '75 the fry-pan handle was so annealed that it wouldn't hold up a single egg. Is this what has happened to my exhaust retainer?

The real question is: would a replacement work better or are they soft from the factory?

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post #2 of 2 Old 04-23-2014, 10:56 AM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,489
I think I have the same old BSA mess kit. Still use it occasionally.
I think my handle got annealed, pouring cold water into a hot skillet to clean.

My '87 exhaust collar is still straight.
You maybe a 'little' stronger, than you think. (over-torqueing)
I'll suggest a New One and a new gasket, and Never re-tighten when hot.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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