Did the header very on length like 3" from 87-07? - 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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  • 2 Post By pdwestman
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post #1 of 6 Old 03-19-2017, 10:49 PM Thread Starter
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Did the header very on length like 3" from 87-07?

I got a header and slipon on craigslist and the header looks almost the same. It has the guard with the same plate but I noticed it was 3 inches longer than mine. I tried slipping the slip-on on my header pipe but my header was a couple mm too wide. It was able to slide perfectly over the header it came with. I'll swap out the headers and see but was wondering if they varied. Mine was nice and clean looking versus the rusty one I bought =/. I'm sure I can wire brush it and hit it with some satin black header paint.

Edit: Put the other header on and it fit just fine with the slip on. The Jardine slip on was really loud so I opened it up and half the packing was gone. Time to hit the local yamaha dealer for some fiberglass packing.

Last edited by jeffrimerman; 03-19-2017 at 11:32 PM.
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post #2 of 6 Old 03-20-2017, 01:32 PM
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Jeff,
All of the OEM '87-'07 black painted 'stainless steel' header pipes came with 2 mounting tabs welded on for the factory screwed on Heat Shield. They are identical in length and diameter to the '08-'17 brushed 'stainless steel' header pipe. ('08-'17 has a smoother, more efficient bend at the front.) These two headers are a direct interchange, as are all years of OEM (quiet) mufflers.

The header pipe and muffler which came on your Used Bike must have been a "Complete Racing System". Therefore neither the header nor the muffler are compatible with anything else.
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 6 Old 03-20-2017, 03:08 PM
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Yep; what Paul said. I have Gen2 headers on both my Gen1's

Dave
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post #4 of 6 Old 03-20-2017, 05:08 PM Thread Starter
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Maybe I should look for a nice shiny 08 and newer header, hmmm. I wonder if someone cut my "original" one. It's for sure shorter or maybe it's off a similar 1 cyl Kawi. I thought something was odd when I tried to take off the oem muffler and the nut was hidden behind the frame but the youtube showed it clearly easier to access. Thanks guys.
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post #5 of 6 Old 03-20-2017, 07:57 PM
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Quote:
Originally Posted by jeffrimerman View Post
Maybe I should look for a nice shiny 08 and newer header, hmmm. I wonder if someone cut my "original" one. It's for sure shorter or maybe it's off a similar 1 cyl Kawi. I thought something was odd when I tried to take off the oem muffler and the nut was hidden behind the frame but the youtube showed it clearly easier to access. Thanks guys.
Jeff,
You talked about a diameter difference as well as the length difference.
The OEM muffler to header joint clamp has always been behind the rear brake reservoir. One doesn't need to disturb it very often!

pdwestman
Modify at "YOUR OWN RISK"!

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post #6 of 6 Old 03-21-2017, 12:59 AM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Jeff,
You talked about a diameter difference as well as the length difference.
The OEM muffler to header joint clamp has always been behind the rear brake reservoir. One doesn't need to disturb it very often!
Yeah I know it was odd. Perhaps the header I had and exhaust were off another bike? I was also thinking maybe someone cut a stock header short for some reason and the pipe was a couple mm wider where they cut it. The other problem was that the joint clamp was not behind the brake reservoir. I took it off just like the video showed but the clamp was farther to the front behind the frame. I tried to reach it from the side with a 13 mm open end but I only had 12 and 14mm =(. I rigged a 1/4" drive 13mm socket to a flathead screwdriver then grabbed it with channel locks. It kept falling apart until it got loose enough. It was so annoying. I kept thinking who the heck would design it like that. I'm sure a previous owner swapped out the aftermarket exhaust and used whatever they could fine. The Jardine slip on is way too loud. I'll probably sell it and put the stock back on for now. I wish I would have take an picture with the headers side by side.
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