Stock Muffler Mod - 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 10-08-2008, 10:06 PM Thread Starter
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Stock Muffler Mod

Don't think I've seen this one here and thought I'd share. I did it this evening and it's just like snakeshack says in the first post. I will say that being a machinist by trade and having access to a shop is key. Building a drill guide for the 10-32's is a plus as the drill will want to drift off location without it, even if you centerpunch first. The holesaw operation is a PITA as described and you must use a guide for the 1/4" pilot. I made one to fit from a small length of bar stock.

I was ready to buy an aftermarket slip on until I met a fellow with another '08 that had a Jardine....too loud for me. This mod gives a subtle but not loud exhaust note, just right for me. There seems to be a small gain in power in the upper rev area. Very nice, cheap mod.

Gray-haired riders donít get that way from pure luck.


Last edited by flash; 10-09-2008 at 06:26 AM.
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post #2 of 2 Old 10-20-2008, 10:35 PM
Join Date: Sep 2008
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I gutted everything out of the stock muffler and used a stock tip off an suzuki quad over the guge hole left in the stock pipe..sounds alot better,,didnt have to rejet,,good thump,,but not lout enough for me..I need the rear loud thump.I didnt have to rejet,,only turn out the mixture screw a little..stock is still too restrictive..yuk.
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