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.