Exhaust Port Leak - Kawasaki KLR 650 Forum
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post #1 of 4 Old 12-20-2012, 08:24 PM Thread Starter
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Join Date: Oct 2012
Location: Silver City, NM
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Exhaust Port Leak

Since I've owned this bike - about 2 months now - I've been grumbling about the spitting sound of the exhaust. I'd swear it was an exhaust leak, but the local shop said, "it sounds like a KLR." 'Course, he's peeved 'cause I didn't buy it from him.

I finally remembered to order a new copper gasket and installed it today. Kawi engineers may have made it harder to get the bloody thing out, but I'm not sure how they'd go about it.



When I finally got it out of there, this is what I found. Looks to me like that lower right corner of the pipe and lower left of the gasket have been leaking for quite a while. (flip the gasket and it lines up with lower right in real life) I polished it up pretty good before re-assembling with new gasket and was real careful about even tightening.

When done I went for a very short test run and to my ear it sounded much better. Still sounds like popcorn farts in a beer can, but doesn't have that sharp chk chk chk chk sound now. (that's the only thing I don't like about my Kawi - I hate the sound of the exhaust - I wish it had the smoother note of every other bike on the road) It still has a bit of the sharp firecracker sound on deceleration, but not as bad. A longer ride tomorrow will show it up.........and I plan to do 15 miles on gravel, too.

..............Lar.
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post #2 of 4 Old 12-20-2012, 11:01 PM
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I use some high heat silicon to help hold it in place when I install new gaskets. There is a 50% chance it will move after you let go of it when you start to get the header pipe in place. The silicon will burn off, it's there just to hold it for a second or two.

Try it this way IF you have to do it again......but I doubt it if you are hearing a better sound now. Now it will come down to where is the sound coming from that is upsetting you to figure out if it's the tweety or another leaking seal. Perhaps the middle joint. If you aren't careful that can leak. If it does badly it will try and burn a hole in the bottom of your airbox......ask me how I know.........

Willys
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post #3 of 4 Old 12-20-2012, 11:36 PM Thread Starter
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Quote:
Originally Posted by willys View Post
I use some high heat silicon to help hold it in place when I install new gaskets. There is a 50% chance it will move after you let go of it when you start to get the header pipe in place. The silicon will burn off, it's there just to hold it for a second or two.

Try it this way IF you have to do it again......but I doubt it if you are hearing a better sound now. Now it will come down to where is the sound coming from that is upsetting you to figure out if it's the tweety or another leaking seal. Perhaps the middle joint. If you aren't careful that can leak. If it does badly it will try and burn a hole in the bottom of your airbox......ask me how I know.........
Haha.......I think I can figure that out. I used the white paste that's made for exhaust systems to hold that copper gasket in place - and it doesn't burn off. I used it on my Diesel Dodge exhaust - post turbo - and had no problems with it. Yah, I've paid my dues with slipping gaskets, too. :-(

When I installed the Lexx muffler, I went by their instructions and used black hi-temp silicone where the muffler slides onto the pipe. Should be good to go now........and I feel much better about the leak. Now I know for sure it isn't coming from the exhaust port.

If it wasn't so much different I'd pull a muffler off the little 500cc Honda Shadow (for sale) and stick it on there for a trial. The Honda sounds great....just exactly how I'd like my Kawi to sound - single cylinder style.

Thanks............Lar.
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post #4 of 4 Old 12-21-2012, 05:26 AM
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Quote:
Originally Posted by biglar View Post
I finally remembered to order a new copper gasket and installed it today. Kawi engineers may have made it harder to get the bloody thing out, but I'm not sure how they'd go about it.
Ha, now that's funny right there!!! Makes you wonder sometimes dont it? My dad used to say Japanese engineers design things that way for the American market as retribution for WWII. There are times I find that easy to believe.

One other thing comes to mind you may check is the air injection port at the top of the head. Some folks are plating that off and removing the associated plumbing. They say it helps remove the pop on de-cel. Mine is still on but after doing the 22 cent mod all that popping went away.
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