exhaust bolts - Kawasaki KLR 650 Forum
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post #1 of 8 Old 05-16-2012, 08:04 AM Thread Starter
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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 8 Old 05-16-2012, 10:45 AM
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Which bolts do you speak of?

http://dl.dropbox.com/u/28110525/klr/KA-0106-01783.gif
Courtesy of bike bandit.


Edit: I posted the wrong one. My bad.

http://dl.dropbox.com/u/28110525/klr/canvas.png

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 10:49 AM.
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post #3 of 8 Old 05-16-2012, 11:27 AM
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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 8 Old 05-16-2012, 03:03 PM Thread Starter
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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 8 Old 05-26-2019, 12:46 PM
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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 8 Old 05-27-2019, 10:39 AM
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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.

Dave
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post #7 of 8 Old 05-27-2019, 04:46 PM
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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 8 Old 05-29-2019, 12:36 PM
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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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