Header bolts come loose??? - Kawasaki KLR 650 Forum
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post #1 of 10 Old 10-04-2015, 04:01 AM Thread Starter
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Header bolts come loose???

Hey guys, I went for a ride last night, and about halfway through, my bike got super loud, and seemed to backfire a lot. I kept riding and didn't really do much about it, because I kinda like the noise :P, but I'm sure I should fix it soon. this morning, I had a look at the header pipe, and discovered that I've lost the bolts somewhere. So the header is loose, which I imagine isn't a great thing for the bike. My questions are,

1, Is this normal to happen at about 6000km?
2, Does anyone know what size bolt I need to tighten it back up? I read it's an M8X1.25, but since I know nothing about bolts, I don't really walk into a shop and buy the wrong thing

Thanks in advance
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post #2 of 10 Old 10-04-2015, 08:07 AM
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The KLR doesn't have exhaust header bolts, it has studs. The removable part should be only the nut, not the whole threaded rod.

The nuts are known to come loose occasionally. The stock nuts are acorn nuts with flanges (i.e. a closed, rounded top instead of a hole all the way through and a wide seat, kinda like a washer but part of the nut). A regular 8x1.25 will work OK. Flange nut better. Flange acorn nut even better. Make sure any acorn nut is deep enough since some are pretty shallow.

If there's no threaded stud there, then you have bigger problems. Could be a PO has removed the stud and installed bolts. Wouldn't be my choice. I'd recommend replacing the stud if it's not there.
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post #3 of 10 Old 10-04-2015, 08:08 AM Thread Starter
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Ohh yeah, I meant nuts...
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post #4 of 10 Old 10-04-2015, 08:32 AM
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Exhaust

You didn't list what year your bike is, but I'll assume it's a Gen-2.

Here's a link to a parts listing for the exhaust parts.
2011 Kawasaki KLR650 (KL650EBF) Muffler(s) | Babbitts Kawasaki Partshouse

Nuts.. P/N 92210-1132 ( says it's a 8mm. )
Gasket.. P/N 11030-1108

Both should be available from a Kawasaki dealer.
You could probably get the nuts from your local hardware store.
Be sure to do proper torque on the nuts, and re-check the torque every 1,000 miles or so. ( 15 ft lb's )
I checked mine at 500 miles, 1,000 miles after re-installation.

Ageing Gracefully



2017 Yamaha XT250
1990 Honda NX250 (Green/White)
2011 Kawasaki KLR 650 (Orange & White )

My KLR Page..http://www.powers31.info/2011_KLR650.htm

Mod's to KLR:
Power socket, L.E.D. Battery Indicator, Camera bag holder
Custom Saddlebag frames .
Louder horns, Firstgear Onyx tail bag.
Custom Aluminum Skid Plate.
Cut down seat with Custom pad.
Go Pro Camera mount.
Doo-Hicky

Last edited by larry31; 10-04-2015 at 08:35 AM.
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post #5 of 10 Old 10-04-2015, 03:51 PM
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Larry has a good point -- if the exhaust header loosened up enough for a nut to go missing there's a possibility for the header to beat the gasket to bits.

Like this example after a long gravel road
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post #6 of 10 Old 10-04-2015, 07:38 PM
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Header

Quote:
Originally Posted by Grinnin View Post
Larry has a good point -- if the exhaust header loosened up enough for a nut to go missing there's a possibility for the header to beat the gasket to bits.

Like this example after a long gravel road
Mine looked a lot like that one.
With the combination of gasket thickness, and cap nuts, using the proper torque seems real important.

Ageing Gracefully



2017 Yamaha XT250
1990 Honda NX250 (Green/White)
2011 Kawasaki KLR 650 (Orange & White )

My KLR Page..http://www.powers31.info/2011_KLR650.htm

Mod's to KLR:
Power socket, L.E.D. Battery Indicator, Camera bag holder
Custom Saddlebag frames .
Louder horns, Firstgear Onyx tail bag.
Custom Aluminum Skid Plate.
Cut down seat with Custom pad.
Go Pro Camera mount.
Doo-Hicky
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post #7 of 10 Old 10-04-2015, 08:17 PM
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I seem to have trouble with one of my header nuts. I haven't found something the right thing to prevent it from loosening. I try to remember to check it at least once a week. I've had it fall off in less than two weeks, even when properly torqued.

My way of saying that my experience is that the nuts loosen fairly regularly and need to be checked.
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post #8 of 10 Old 10-05-2015, 08:50 AM
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Quote:
Originally Posted by tjduexjr View Post
I seem to have trouble with one of my header nuts. I haven't found something the right thing to prevent it from loosening. I try to remember to check it at least once a week. I've had it fall off in less than two weeks, even when properly torqued.

My way of saying that my experience is that the nuts loosen fairly regularly and need to be checked.
Safety wire?
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post #9 of 10 Old 10-06-2015, 01:51 AM
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Star washers and/ or red loctite.

This is my son, with whom I am well pleased." ----God
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post #10 of 10 Old 10-06-2015, 07:08 PM
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header nuts

Quote:
Originally Posted by tjduexjr View Post
I seem to have trouble with one of my header nuts. I haven't found something the right thing to prevent it from loosening. I try to remember to check it at least once a week. I've had it fall off in less than two weeks, even when properly torqued.

My way of saying that my experience is that the nuts loosen fairly regularly and need to be checked.
Is your gasket crushed? You may need a new gasket. I replaced my gasket, and used OEM nuts. Checked torque several times this summer. After 2d check ( needed very slight tightening ) it was same torque setting every time I checked it after that..

Ageing Gracefully



2017 Yamaha XT250
1990 Honda NX250 (Green/White)
2011 Kawasaki KLR 650 (Orange & White )

My KLR Page..http://www.powers31.info/2011_KLR650.htm

Mod's to KLR:
Power socket, L.E.D. Battery Indicator, Camera bag holder
Custom Saddlebag frames .
Louder horns, Firstgear Onyx tail bag.
Custom Aluminum Skid Plate.
Cut down seat with Custom pad.
Go Pro Camera mount.
Doo-Hicky
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