Rattling Exhaust Cover - Kawasaki KLR 650 Forum
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Old 03-24-2018, 10:13 PM Thread Starter
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Rattling Exhaust Cover

Tightened both the Allen bolts but it still rattles with any acceleration. And it is loose to the touch like it's somehow not tightened down. Any ideas on how I can put an end to this maddening situation?

To be clear, this is the silver/chrome cover over the exhaust pipe toward the bottom of the bike. Part 49107 on the BikeBandits part diagram.


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Old 03-24-2018, 11:11 PM
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DAMPER 92161-0306 $2.65

You need two. Buy six. They only last a couple of years.
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Old 03-25-2018, 04:43 PM
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No need to purchase new dampers.

Shorten the inner collars #92152-0620 with a grinder or file about a millimeter or so. So that there is some Compression of the damper.

Firms the mounting right up!

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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Old 03-25-2018, 10:41 PM
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Originally Posted by Coverscout View Post
Tightened both the Allen bolts but it still rattles with any acceleration. And it is loose to the touch like it's somehow not tightened down. Any ideas on how I can put an end to this maddening situation?

To be clear, this is the silver/chrome cover over the exhaust pipe toward the bottom of the bike. Part 49107 on the BikeBandits part diagram.


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I had the exact same problem I simply got 2 more washers for each bolt added them on and viola problem soveld.
Think it cost me like 12 cents

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Old 03-26-2018, 07:10 AM
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Originally Posted by BackcountryBob View Post
I had the exact same problem I simply got 2 more washers for each bolt added them on and viola problem soveld.
Think it cost me like 12 cents
I need to do this. After finishing up my 685 kit this weekend, my engine was much quieter (mostly from the new exhaust gasket, I think I had a leak) and had noises... first I adjusted the Doo and it sounded different, but still a rattle.. turns out it's my heat shield. the bike was probably too noisy to hear it before.

"It sure beats working all week, boozing it up in some smoky bar or sitting around watching the world go to Hell in living color and still ending up, just before payday, flat broke as usual. That's only existing, not really living." - Don Marshall, Cycles South, 1971
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'08 KLR650 & '14 Super Tenere
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Old 03-26-2018, 09:01 AM
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Originally Posted by bryce View Post
I need to do this. After finishing up my 685 kit this weekend, my engine was much quieter (mostly from the new exhaust gasket, I think I had a leak) and had noises... first I adjusted the Doo and it sounded different, but still a rattle.. turns out it's my heat shield. the bike was probably too noisy to hear it before.
Hope its a simple.fix like mine was.. It's at least a place to start before running out and spending money on dampners. Something I have found is that KLRs and their owners tend to be cheap... And not in a negative way they are clever cheap. If there's a way to fix it without much money KLR owners know how to do it.
Hope it works out bud

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Old 03-26-2018, 09:16 AM
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Originally Posted by BackcountryBob View Post
Something I have found is that KLRs and their owners tend to be cheap... And not in a negative way they are clever cheap.
I'm gonna try that first if there's enough material left. It seems that a lot of the rubber type stuff on my '08 has rotted away (wind screen well nuts in the first year, most recently, the boot on the battery cable for the starter. Though it may have been rotten for a long time and just never noticed until I pulled the starter off to do the 685 kit.


Going off track (sorry)... Some are downright cheap!!! my Favorite Cheap KLRista story is from back in '08. I got my '08 in January '08 and hadn't seen any other Gen IIs in the wild by this time. I finally saw another at a gas station and waited for the owner to appear to talk to him. As we're waiting, there's a guy digging through the trash. I was saying to myself, I knew the reputation of a KLRista, "Please don't be the guy on the bike", because that would solidify the stereotype. Yep, it was him. His story was he was really a Harley rider, but had to sell his real bike and get the KLR becasue it was cheap (like him I guess) and that certain scratch off tickets had a 2nd chance drawing you could send in to try to win... he was especially interested in finding a certain one that had a drawing for a new Harley.

This was my first time seeing a Gen II KLR in the wild and the first time meeting a KLR rider that I didn't already know.
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"It sure beats working all week, boozing it up in some smoky bar or sitting around watching the world go to Hell in living color and still ending up, just before payday, flat broke as usual. That's only existing, not really living." - Don Marshall, Cycles South, 1971
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'08 KLR650 & '14 Super Tenere
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Old 03-26-2018, 09:20 AM
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Hahahaha dude that's absolutely great. Thanks for the story that made my morning!!

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Old 07-07-2019, 06:10 AM
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Quote:
Originally Posted by Tom Schmitz View Post
DAMPER 92161-0306 $2.65

You need two. Buy six. They only last a couple of years.
They are $4.67 in 2019.
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Old 07-07-2019, 06:39 PM
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Originally Posted by Lake Abilene View Post
They are $4.67 in 2019.
I'll suggest that one grind the center steel spacer Shorter, so the Old rubber dampers actually gets some Compression to Hold the heat shield tighter and then it Can't wear-out the rubber grommets.

pdwestman
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