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Premium Member
2018 KLR650
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366 Posts
That looks ugly. Hopefully there is not very much damage done. I am a bit terrified of burning holes in the clean air side of my air box.

I routinely check the torque of the foot peg bolts, sub frame bolts, muffler clamp bolts and header bolts.

I have never found the foot peg bolts to be loose, but others have. I have lost a sub-frame bolt, and I have found the muffler clamp bolts and header bolts to be slightly under torque more than once. I think the heating and cooling of the exhaust may cause looseness.

It is advisable to check these bolts regularly
 

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Premium Member
2018 KLR650
Joined
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366 Posts
You should consider wrapping your exhaust as an extra precaution. I would recommend using 1" wide wrap.
Thanks for your advice 2ball. I don't think I really need to wrap my exhaust. I know that a lot of people do it, but I think a lot of the issues are with after market systems.

From what I've read and seen on other's bikes the main issues are melting the little inlet at the bottom of the coolant overflow bottle and the burning holes in the air box issue.

I think the overflow bottle issue is pretty much a after market exhaust thing. I've had a couple of KLRs and do daily commutes in stop start traffic with ambient temperatures sometimes exceeding 110°F and had no plastic melting issues at all.

I do the normal maintenance which includes checking fasteners, so hopefully, the muffler clamp shouldn't leak.
 

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Premium Member
2018 KLR650
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366 Posts
The exhaust AIS on Gen 2's & Gen 3's creates a LOT of heat! Best to keep the bikes moving.
CAVEAT: I read this from PDWestman's post above and realised I have no idea what an AIS is. So, I did a bit of research, and realised that Australian KLRs do not have one!

It seems the presence of an AIS increases the likelihood of melted nipples and things. So, my comments about not needing exhaust wrapping and larger heat shields might be wisely ignored by North American Riders
 

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Premium Member
2018 KLR650
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366 Posts
AntonK asked, "I am curious PD - my understanding is that lean mixtures create excessive heat not rich...so how come the bike did all that melting with the choke on? "

The Exhaust AirInjectionSystem into the exhaust port from between the spark plug & ex cam area (on Gen 2 & 3 North American models only??) burns the overly rich fuel mixture in the header pipe, creating intense heat.

But even Gen 1's without AIS have been known to heat collapse the reservoir nipple closed.
Many owners have suggested that the factory may have even forgot to drill a hole thru the bottom nipple, which is possible.


I'm totally surprised & you Australians are lucky, maybe!

Are the Gen 3 Australian KLR's still LearnerApprovedModels ?
If so, are they still tortoise slow & how?
You said Maybe. Good call. I am only pretty sure about the no AIS, but I am pretty sure.

The 2022 does offer LAMS. Not sure if it's an option or no choice like previous models. I'll find our and let you know
 
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