Smoke Billowing From Mid Pipe/Header Joint on Lexx Exhaust - Kawasaki KLR 650 Forum
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post #1 of 6 Old 04-28-2015, 07:23 PM Thread Starter
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Smoke Billowing From Mid Pipe/Header Joint on Lexx Exhaust

Hi Guys,

I just installed a new Lexx Exhaust on my 08. Used high temp silicone as instructed, and it all went smoothly. After letting the pipe sit for a couple days, I started it up for the first time, and smoke is billowing it of the joint where the header pipe meets the mid pipe.

Here's an image of the smoking joint:


The odd part is that there is no smoke at all coming out of the muffler, and the bike is running with Zero issues at all. There is definitely healthy airflow coming out of the muffler, yet this heavy smoke is billowing out of the joint every time the cylinder fires.

My only thought is that there is too much resistance in the muffler, causing smoke to come out of the joint. I'm gonna contact Lexx and see if they have an answer as well.

Does anyone have any experience with this?

Sincerely,
Confused in California

Last edited by Tom Schmitz; 04-28-2015 at 07:51 PM.
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post #2 of 6 Old 04-28-2015, 08:19 PM
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I can only guess that the silicone is heat curing. Or oils from your hands are burning off.

I wish the aftermarket pipes would use the gasket like Kawasaki does!

If you hold a piece of paper or a feather near the joint, does it "flutter"?
That would indicate an Exhaust Leak!

I had to rebuild my 1987 KLR650A1, partly because of an Exhaust Leak in that very area. The leak burned a hole thru the clean-side of the air filter box. Allowing dirty air into my engine!

The newer bikes do have kind of a heat shield in that area. But I have seen a mounting screw melted OUT!

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post #3 of 6 Old 04-28-2015, 08:20 PM
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Maybe the silicon cooking???

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Wisdom is knowing whether or not to say it.
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post #4 of 6 Old 04-28-2015, 09:57 PM
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I used my stock Kawi gasket on mine. Fit right on. I never had any smoking issues.

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post #5 of 6 Old 04-28-2015, 11:12 PM Thread Starter
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Hi fellas,

It seems unlikely given that I've never had problems with this silicone before, but who knows, exhausts do get pretty darned hot! Must be it..... I'm going to see if I can pull the gasket off the old muffler and report back.

PDwestman, there is undoubtedly an exhaust leak, thanks to the heavy you can see it puffing right out sans paper.

Cheers for the insight guys.
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post #6 of 6 Old 04-29-2015, 08:10 PM
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It's been a couple years since I installed mine, but I remember thinking "how the heck is this going to stay together?" So I thought I'd see if the stock pc would work, and it did!

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