New End Cap, stock pipe? - Kawasaki KLR 650 Forum
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post #1 of 9 Old 08-31-2012, 04:15 PM Thread Starter
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New End Cap, stock pipe?

I purchased a new end cap for my 09 stock pipe, what else might I need to change when I install it?
The open bore in the new cap IIRC is about 1.5-2in ID.
I will need to pull the spark arrestor, is there any easier way to install a new one (easier=cheaper)?
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post #2 of 9 Old 09-03-2012, 03:18 PM Thread Starter
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Les I saw you help someone do the same install, is anything
else normally done along with opening the pipe ?
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post #3 of 9 Old 09-03-2012, 04:53 PM
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Your end cap didn't come with a spark arrestor screen? I don't need one where I live, but my cheap eBay cap came with a screen. I keep expecting it to disintegrate when I occasionally stick my finger in there and push on it, but so far it's intact after a couple thousand miles. It kind of looks like a window screen. Legal? Beats me.

How are you going to cut your muffler end out? Hole saw? Drill and chisel? Having taken the drill and chisel route (which worked out fine) I would recommend finding a hole saw and doing it that way.



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post #4 of 9 Old 09-03-2012, 05:00 PM Thread Starter
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Nope a spark arrestor did not come with. I was thinking a small "tea strainer" mesh would work I'm just not to sure how much surface area is needed for the mesh to allow adequate exhaust flow, ie flat across the opening, a 2in deep mesh cup or 6in deep mesh cone??
I am planning to cut the hole with a saw after pounding a dowel in the pipe to take the pilot bit.
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post #5 of 9 Old 09-03-2012, 05:08 PM
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Quote:
Originally Posted by Stinker View Post
I purchased a new end cap for my 09 stock pipe, what else might I need to change when I install it?
The open bore in the new cap IIRC is about 1.5-2in ID.
I will need to pull the spark arrestor, is there any easier way to install a new one (easier=cheaper)?

If you're going to ride somewhere where a spark arrestor is required you're taking a chance cutting out the OEM.

That said get a piece of stianless steel mesh screen, I've cut up a strainer before. Fit it in between the end cap and muffler body. Usually a "check" will be sticking something into the end of the exhaust, if it stops your good. Of course the screen is not an approved spark arrestor even though it will work as one.

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 #6 of 9 Old 09-03-2012, 05:10 PM
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Quote:
Originally Posted by Stinker View Post
Nope a spark arrestor did not come with. I was thinking a small "tea strainer" mesh would work I'm just not to sure how much surface area is needed for the mesh to allow adequate exhaust flow, ie flat across the opening, a 2in deep mesh cup or 6in deep mesh cone??
I am planning to cut the hole with a saw after pounding a dowel in the pipe to take the pilot bit.
My screen is just flat across the opening at the joint where the end cap "pipe" meets the mounting flange. It seems to work fine.

Good call on opting for the hole saw technique.

For the record, I just used self-tapping sheet metal screws to attach the cap instead of threading holes for bolts. I then used small dabs of JB Weld on the head of each screw to keep them from coming loose. So far it's worked. Figure if I ever have to take it off, I can get the JB Weld "tacks" off.



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post #7 of 9 Old 09-03-2012, 09:05 PM
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post #8 of 9 Old 09-03-2012, 10:31 PM
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I didn't wanna drop $25.00 bucks on the hole saw so I ended up drilling 4 holes in the muffler, one top and bottom then side to side. Then I used a electric jigsaw and it worked great. The holes were to help steer the jig saw and turning points. A 3 dollar jigsaw blade did well.



'Life's Journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sideways,totally worn out, shouting, 'Holy shit .... What a Ride!
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post #9 of 9 Old 09-03-2012, 10:31 PM
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Quote:
Originally Posted by Stinker View Post
I purchased a new end cap for my 09 stock pipe, what else might I need to change when I install it?
The open bore in the new cap IIRC is about 1.5-2in ID.
I will need to pull the spark arrestor, is there any easier way to install a new one (easier=cheaper)?
Do the .22 mod, open the fuel screw, remove the airbox snorkle. Ride and enjoy!

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