KLR250 stock muffler mod with pics
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Author Topic: KLR250 stock muffler mod with pics  (Read 2601 times)
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ilovewvmountains
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« on: August 22, 2011, 07:18:35 PM »

I decided to take a chance and hack up my stock muffler… I figured if I ruined it I could just replace it with an Ebay special or an aftermarket muffler!  Anyway I started by removing the stock baffle, it was rusted in there pretty good and the bolt had to be drilled out… Not a problem!   After that I thought about how to remove the swirl shaped spark arrestor from the back of the muffler… I took a long socket extension and tapped it down in there to break the welds loose… I thought I could then pry it out, no luck I actually pressed it into the pipe further!  I was able to use a long drill bit and drill a hole right in the center of it, its cone shaped by the way.  Once I did that I took the drill and drilled the fins around the cone a little just to bend it up.  I made a long wire hook and was able to work it out enough that I could get ahold of it with long needle  nose pliers.  If I did it again I would use a hole saw on a drill bit extension and cut it out, the welds did snap off fairly clean so for now Im happy with it!  I planned on it being really loud with all of the guts removed but surprisingly its not too bad, sounds like the big fun full system to me.  I am going to modify the stock silencer and put it back in to tone it down some but it is definitely breathing better! I just installed a stage 1 Dyno Jet kit in it along with a UNI filter so it’s a combination of the above but its running like a top.  Throttle response is 10x crisper than before and it has more mid and top end power, I can now cruise in top gear at 60 on the back roads without having to down shift all the time so Im happy! Anyway, here is a link to a few pictures for those that have never seen the inside of a stock muffler!

https://skydrive.live.com/?cid=a132c6a6432774a9&permissionsChanged=1&id=A132C6A6432774A9%21481#!/?cid=A132C6A6432774A9&permissionsChanged=1&id=A132C6A6432774A9%21481&group=0&sff=0
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TrailRider
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« Reply #1 on: August 23, 2011, 12:23:54 AM »

After that I thought about how to remove the swirl shaped spark arrestor from the back of the muffler… I took a long socket extension and tapped it down in there to break the welds loose… I thought I could then pry it out, no luck I actually pressed it into the pipe further!  I was able to use a long drill bit and drill a hole right in the center of it, its cone shaped by the way.  Once I did that I took the drill and drilled the fins around the cone a little just to bend it up.  I made a long wire hook and was able to work it out enough that I could get ahold of it with long needle  nose pliers.  If I did it again I would use a hole saw on a drill bit extension and cut it out, the welds did snap off fairly clean
You may be aware, lovewvmountains, removing the spark arrestor results in a bike illegal to operate in National Forests.

Maybe you never venture onto Forest Service roads or trails, but the regulation's no joke--an element of technical inspection at the forthcoming Shenandoah 500 Dual-Sport Ride, in George Washington National Forest, near you.  And, an element of a Federal citation if caught on Forest lands without the device.

We remember what Smokey the Bear and Woodsy Owl say about forest fires!

Before-and-after mod dyno runs would be interesting.
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ilovewvmountains
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« Reply #2 on: August 23, 2011, 07:41:04 AM »

I know all about the regs! My KLR250 is primarily a back road beater but I do have a screen type spark arestor that I plan on using when I do venture into the woods, I just forgot to mention that last night! 
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davebolden44
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« Reply #3 on: August 25, 2011, 03:47:20 AM »

you may need to rejet your carb now
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davebolden44
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« Reply #4 on: August 25, 2011, 03:48:51 AM »

sorry i see now you already have. maybe i should read the whole thing next time
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ilovewvmountains
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« Reply #5 on: August 25, 2011, 05:31:28 AM »

 Just an update, I was out in my garage last night organizing some stuff and came across the slip in silencer that came with the Staintune exhaust that I have on my Triumph Sprint RS 955i sport bike.  It fits snugly in the opening of the stock pipe!  I’m going to have to have it straightened out a little or cut some off of it as its angled for the Staintune pipe and doesn’t slip all the way in strait but it tones the exhaust down perfectly and they are only $35!  You don’t get the weight savings of a full system or aftermarket muffler but doing all of this really does open it up! Here is a link to the slip in Staintune baffle for those that don’t know what Im talking about!  "It’s the basic 48mm type."
 http://www.calmoto.com/SHOP/stntnrestrictor.html
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ilovewvmountains
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« Reply #6 on: August 25, 2011, 10:51:47 AM »

Im for it!!!
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TrailRider
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« Reply #7 on: August 27, 2011, 09:41:03 AM »

Count me in!

If water crossings involved, "Tee Mods" might be recommended!

(Do not ask why I offer this suggestion.)
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