08 aftermarket exhaust - Kawasaki KLR 650 Forum
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post #1 of 8 Old 03-26-2008, 06:01 PM Thread Starter
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08 aftermarket exhaust

I just bought my KLR and I am looking to upgrade the exhaust. If i get aftermarket exhaust will I have to re-jet the carb? Could I do this myself? Should I wait until the warranty is up? Lots of questions. I havent had a dual purpose motorcycle in a long time. Thanks in advance for your time.

Todd Nichols
Washougal, Washington
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post #2 of 8 Old 03-26-2008, 08:03 PM
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Everyone has their favorite exhausts, but my buddy and I both just finished putting on Jardine pipes and added after market air filter and rejetted the carbs. I am still amazed at the power gain you get from this. Twist the throttle and the front wheel likes to reach for big air, even with my BIG butt sitting on it. My buddy is running a 16 tooth front sprocket and has NO problem pulling wheelies.
www.klr650.com for pipe and filter/jet kit. Our pre 08 bikes had 148 Main jets, yours should have a 145 if i am not mistaken. We ended up having to get 152's and using the studebaker needle set on the 4th notch to get a nice plug color. Or I have a nice new KLX needle that should work with your stock jet just fine, if you do the pipe and airfilter together. I'll even kick in a 148 and 150 Main Jet for you plus the drill bit to drill the needle slide to allow for quicker response. I have it listed in the classified section.

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Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 8 Old 03-26-2008, 09:59 PM Thread Starter
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Hey DXKLR,
I was looking at your upgrades and wanted to ask you about the fuses to breakers and safety switches bypassed. What does that do for you?

Todd
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post #4 of 8 Old 03-26-2008, 11:18 PM
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The breakers simply keep you from having to carry extra fuses as you can reset the breakers by simply turning off the key and then back on again. Obviously if one has tripped you want to trace down the problem, but after that, just turn key back on and you are ready to go again. The Kickstand and cluth by passes are more of a safety issue to some of us than others. If the clutch by pass goes out, and you kill the bike in the middle of the road, you can't just hit the starter and start it back up, you got to down shift and find neautral to get the bike to restart. That can get you ran over if your on a busy road. The kickstand switch is as bad, in that if it goes out, your bike just simply aint going to start till you either fix the switch or you go ahead and bypass the switch. By by passing them I don't have to worry about them. Yes you DO need to remember to put that kickstand up as you will be able to put the bike in gear and drive off with it down, but I was brought up old school and never had all these lawyer proof gadgets before, so I know to always check my stand. Hope this helps some.

I know you can do the side stand by pass, but I am not sure your wiring for the clutch safety is the same. I need to look at my buddies bike to check that out. He only wanted the side stand done, but didn't have me do the clutch for some reason.

Also the fuses on all the pre 08's are the old glass style buss fuses, another reason to change them out, I think that you have the mini two blade fuses in yours, and if that is right you should be just fine with that set up. I keep forgetting the 08's are just "that" much different. Wanderer is right, I think we need a section for the 87 to 07 bikes and then a new section for the 08 and up bikes so we don't get too confused on mods for each style. I just happened to notice in your previous post you have an 08, you might want to update your signature with your bike year and also put in where you are located. That helps us out sometimes in that if someone is near they could possibly be of help doing some wrenching...

Heres the link for by passing switches:
http://www.klr650.marknet.us/Safety_Bypass.pdf

Link for Circuit Breakers:
http://www.geocities.com/MotorCity/D...4/page122.html

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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Last edited by DXKLR; 03-26-2008 at 11:24 PM.
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post #5 of 8 Old 03-27-2008, 09:56 AM Thread Starter
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Thank you for all the information. I noticed you had side cases on your bike in the pics you took when you put your exhaust on. Where did you get those? Are they Kawasaki OEM parts?

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post #6 of 8 Old 03-27-2008, 11:33 AM
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They are Pelican 1430's that I got off of ebay. About 150 for both shipped. We made the mounts ourselves.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #7 of 8 Old 03-27-2008, 11:43 AM Thread Starter
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How easy was it to make the mounts?

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post #8 of 8 Old 03-27-2008, 05:54 PM
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If you can weld and have some creativity, not too difficult. I think we took about an hour or so to make mine. Of course like anything, after the first one is made the second one goes twice as fast. I did have to cut the grab bars off of my rear rack in order for the pelicans to sit as close as possible to the bike. I have no issue doing this, but some would wince and shed tears over doing that kinda thing. It just all depends on what you want and are willing to do to have it.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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