exhaust bolts - Kawasaki KLR 650 Forum
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post #1 of 12 Old 05-16-2012, 07:04 AM Thread Starter
Join Date: May 2012
Location: northeast PA.
Posts: 5
exhaust bolts

What are the bolts on bottom of exhaust for?I don't have a owner manual.Order a service manual it has not come in yet. Fritz
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post #2 of 12 Old 05-16-2012, 09:45 AM
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Location: Rolla, Mo
Posts: 576
Which bolts do you speak of?

Courtesy of bike bandit.

Edit: I posted the wrong one. My bad.


I think you are talking about 92154. To be honest, I'm not sure what it does either.

Last edited by steferf; 05-16-2012 at 09:49 AM.
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post #3 of 12 Old 05-16-2012, 10:27 AM
Join Date: Jan 2011
Location: NW MO
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If you're talking about the big plug-looking things, they're supposedly to "blow carbon particles out of the exhaust baffle."

You're supposed to remove the plugs, start the engine, rap the throttle and bang on the muffler with a rubber mallet, then temporarily place a towel over the end of the exhaust so it comes out through those two holes and blows out carbon particles.

All my dualsports have had them but I've never taken them out. My KLR no longer has a baffle so it doesn't matter.

In theory, anyway, that's their intended purpose.

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post #4 of 12 Old 05-16-2012, 02:03 PM Thread Starter
Join Date: May 2012
Location: northeast PA.
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Yea the plug looking bolts. I don't think I've seen any on any of the other bikes I have owned. thank for info. Fritz
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post #5 of 12 Old 05-26-2019, 11:46 AM
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Join Date: Mar 2019
Location: So. Cal.
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Old thread but I have some input. Donít bother with these bolts. Iím a new KLR owner of a used 2014 with 4200mi. Iíve been performing all the checks and maint that may have not been done. Removing the 4 exhaust clean out bolts carefully I could feel binding and seizing of the bolts. The boltís threads were scared and had metal from the exhaust threads in them. I performed the exhaust clean out procedure and not 1 flake of anything came out of the 4 holes. I chased the exhaust threads with a 12mm x 1.25 tap and got quite a few small shavings. I also cleaned out the bolt threads with a thread file getting all the rings of metal debris out. All 4 bolts were then able to be put in easily by hand and a quick final torque with a wrench. I did apply a small amt of grease. Bottom line, Iíll never remove these bolts again. Waste of time unless your bike is running really dirty. (Rich or burning oil)
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post #6 of 12 Old 05-27-2019, 09:39 AM
5th Gear
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,647
I always tell people to leave those bolts alone; the whole procedure is absolutely a waste of time and completely unnecessary.....all you'll get for your trouble is a stripped bolt.

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post #7 of 12 Old 05-27-2019, 03:46 PM
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Join Date: Mar 2019
Location: So. Cal.
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Thanks Dave. Agree 100%. Wasted 30 minutes cleaning out threads just to get them back in.
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post #8 of 12 Old 05-29-2019, 11:36 AM
2nd Gear
Join Date: May 2018
Location: Michigan
Posts: 271
If you have a bike year 2010 or newer with the catalytic converter, your exhaust gets hot enough in the converter to pretty much completely eliminate any carbon buildup within the baffle. My 2018 exhaust is so hot the header pipe glows cherry red at night. That with the air induction + converter that makes H2O = little to no carbon buildup.

Never pick a fight with an old man.. If he's too old to fight, he'll just kill you..
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post #9 of 12 Old 02-20-2020, 11:01 AM
Join Date: Feb 2020
Location: Upper Bucks County Pennsylvania (east side of state)
Posts: 6
I wish I had found this info before attempting to take mine out. Very difficult to remove. The plug threads are good for about 1/4" near the hex end, then stripped from there up. I have new ones on order, but I wonder if I should cut them shorter. I assume the good threads on the old plugs were seated in the threaded "bungs" on the muffler, and the stripped off part was up in the exhaust blast since '09. Either shortened, or full stock size, the new ones will be well coated with never-seize when they go back in. Oh yes, virtually no soot came out. I really wanted to see clouds to justify my efforts.
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post #10 of 12 Old 02-22-2020, 10:41 AM
1st Gear
Join Date: Mar 2019
Location: So. Cal.
Posts: 17
Sorry Art. Same here. Didnít search here first (which I always do now). My threads were more gauled and filled with metal. (I think thereís a dis-similar metal issue there) A thread file cleaned them up perfectly. (A neighbor mechanic turned me on to thread files. Bought a nice set of both metric and SAE online for less than $25). Iím sure youíve cleaned out the bosses with a tap. Your new plugs will fall right in never to be bothered with again!
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