With the header pipe mounted, the clearance between it and the acc. pump was about 5/16”.
I didn’t like the pipe being this close due to the heat getting to the fuel pump. Riding at highway speeds a lot may not cause problems due to good air flow but I ride in slow, technical areas often where the air flow would be limited. In order to test the carb out and not be affected by the heat, I decided to offset the header a bit to get it away from the pump. Another possible option that may work is header wrap. I bought a roll of 1” wide titanium header wrap to try in the future.
The closest diameter tubing and elbows I could find to fit the header pipe were 1¾” O.D. thin wall stainless I bought a variety of 45s and 90s to get the offset clearance I wanted. When I received the elbows, the wall thickness on the 45s was different from the 90s. The 90s fit nicely over the outside of the header pipe so this was the best option to use.
The 90 deg. elbow as it came
After trying different routes with the elbows , the angles needed came out very simple. In the end I used three 45deg elbows and one about half that size. These can all be cut from two of the 90 deg. elbows. The only other piece needed was a piece of straight tubing about 2 5/8” long.
This is the offset after tacking
After welding, everything was smoothed out
Even though the fit is close, the carb can be tilted to change jets or access the bottom of the carb.
Even with the offset, the KLR header pipe heat shield can be modified to fit. This pic shows the shield attached with the front mounting screw. I’ve been running the bike without the shield but will mount one later as time allows.
( I usually wash the bike off to work on it but weather didn’t allow a bath before the work started.)
That’s basically how I mounted the carb to fit the KLR and re-routed the pipe for clearance