Wilsons Sandbox

jhenry@... wrote:

>When i purched my 2000 it had the big gun on it, and i want to put >the stock muffler back on. I'm unclear of what is refered to as the >Header Pipe. At what joint, in using the stock exhaust and the big >gun pipe , does this change take place? I notice a pipe over pipe >connection (about 3/4 of the way back or do you some how un bolt the >actual muffler and use the entire big gun pipe. >Should I expect an adjustment needed at the carb. It runs great now, >maybe a little rich for the tip of the muffler is black. >I agree this is a very loud set up.I'll deal with tweety when needed. > >

If it's rich with the Big Gun installed (soot on the tailpipe isn't so reliable since most KLRs burn a little oil at high rpms), then it will definitely be rich with the stock pipe. The previous owner most likely fitted a dynojet kit according to the instructions, which tend to be on the rich side. So you'd set the pilot mixture screw back to something like 2 turns out or 2.5 turns out. Or a turn in from wherever it is now. Every carb is a little different. The FAQ has links to good sites on adjusting the idle mix. You can keep the dynojet needle, but set the clip in the second notch down. Or even the top clip, I'd try the second notch for a while and see how it works. You might want to re-install the stock main jet, a Keihin #148. Be aware that the Keihin and Dynojet numbers aren't on the same scale, so a Dynojet#140 is actually richer than the Keihin #148. Supposedly the Dynojet#136 is equivalent to a Keihin#148, but I think it's still a little richer. The Dynojet needle seems to work fine with the Keihin main jet. Devon

--- In DSN_klr650@yahoogroups.com, Devon wrote:

> > > jhenry@m... wrote: > > >When i purched my 2000 it had the big gun on it, and i want to put > >the stock muffler back on. I'm unclear of what is refered to as the > >Header Pipe. At what joint, in using the stock exhaust and the big > >gun pipe , does this change take place?

The header pipe is the front part of your exhaust. It forms the link from the exhaust port on the front of your motor to the exhaust can, which hangs below your luggage rack on the back of your bike. In addition to making replacement cans, BG makes a replacement head pipe. It's silver in color, coated like a performance car header. Thanks CA Stu

So the header pipe is from the exhaust "can" back. So I will be replacing the "can only". I need to re-look over the stock system to see how this can be done. Is this a matter of simply unbolting and replacement of the "can"? I like the look of the BG header pipe although I learned that don't ever touch skin or mesh material while hot Thanks, Jhenry@... -----Original Message----- From: CA Stu [mailto:s2mumford@...] Sent: Thursday, June 03, 2004 6:01 PM To: DSN_klr650@yahoogroups.com Subject: [DSN_klr650] Re: header pipe

--- In DSN_klr650@yahoogroups.com, Devon wrote: > > > jhenry@m... wrote: > > >When i purched my 2000 it had the big gun on it, and i want to put > >the stock muffler back on. I'm unclear of what is refered to as the > >Header Pipe. At what joint, in using the stock exhaust and the big > >gun pipe , does this change take place? The header pipe is the front part of your exhaust. It forms the link from the exhaust port on the front of your motor to the exhaust can, which hangs below your luggage rack on the back of your bike. In addition to making replacement cans, BG makes a replacement head pipe. It's silver in color, coated like a performance car header. Thanks CA Stu List sponsored by Dual Sport News at www.dualsportnews.com. List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Unsubscribe by sending a blank message to: DSN_klr650-unsubscribe@yahoogroups.com . Yahoo! Groups Links

The header is the curved pipe that runs from the front of the cylinder to the front of the muffler. The clamp joint is behind the rear brake fluid reservoir. The guard has to be removed, and the mount bolt for the reservoir removed so you can push it to the side. You don't need to remove the reservoir. The stock muffler bolts up in two places, not one like most aftermarket pipes. You'll see where the second bolt goes when you pull the seat and sidecover. It's an 8mm diameter bolt if I recall correctly, maybe 10-15mm threaded portion. Hopefully the PO left it in the unused hole when they installed the BG. Devon jhenry@... wrote:

>So the header pipe is from the exhaust "can" back. So I will be replacing the "can only". I need to re-look over the stock system to see how this can be done. Is this a matter of simply unbolting and replacement of the "can"? I like the look of the BG header pipe although I learned that don't ever touch skin or mesh material while hot > > > >

> -----Original Message----- > From: Jim Henry [mailto:jhenry@...] > > So the header pipe is from the exhaust "can" back. So I will be > replacing the "can only". I need to re-look over the stock system > to see how this can be done. Is this a matter of simply unbolting > and replacement of the "can"? I like the look of the BG header > pipe although I learned that don't ever touch skin or mesh > material while hot > > Thanks, > > > Jhenry@...

Yes, it's a simple bolt on procedure. It goes easier with two people, one to hold the can in the right place while the other tightens the mounting hardware. Easy peasy. Thanks CA Stu

CA Stu and Devon, Thanks for the info, there may be a 5000-mile BG available soon, at a reasonable price, for those who want to give it a try Jhenry@... -----Original Message----- From: Stuart Mumford [mailto:s2mumford@...] Sent: Friday, June 04, 2004 2:46 PM To: Jim Henry; DSN_klr650@yahoogroups.com Subject: RE: [DSN_klr650] Re: header pipe

> -----Original Message----- > From: Jim Henry [mailto:jhenry@...] > > So the header pipe is from the exhaust "can" back. So I will be > replacing the "can only". I need to re-look over the stock system > to see how this can be done. Is this a matter of simply unbolting > and replacement of the "can"? I like the look of the BG header > pipe although I learned that don't ever touch skin or mesh > material while hot > > Thanks, > > > Jhenry@...

Yes, it's a simple bolt on procedure. It goes easier with two people, one to hold the can in the right place while the other tightens the mounting hardware. Easy peasy. Thanks CA Stu

Don't take this as gospel, but I believe I have seen pics of a 08+ header on and oldie. -Jeff

----- Original Message ----- From: "Thomas Komjathy" To: "dsn klr650" dsn_klr650@yahoogroups.com> Sent: Tuesday, October 4, 2011 6:15:06 PM Subject: [DSN_KLR650] Header pipe I think it does, but I must ask first. Does the 08-11 header fit the 07 and older models? TK Thomas J. Komjathy DSK L.L.C. dskllc@... [Non-text portions of this message have been removed]