2008 KLR650 Exhaust Recall notice
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Author Topic: 2008 KLR650 Exhaust Recall notice  (Read 30049 times)
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gunny
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« on: October 22, 2007, 06:41:38 PM »
Was at the Kawi dealer today to look at a versey and was talking with the owner about KLRworld. He was asking me about how the guys ride them, off road of course I say. Anyways I was telling him about some of the problems that have been reported like the preload adjuster breaking and exhausts falling off, he pulled a recall notice out about the '08 exhaust bolts. KHI just issued it. Seems there was no torque spec on the exhaust bolts from the factory. The required torque now is 18ftlbs. So ...... get out your trusty torque wrench and loctite and torque to 18ftlbs  Awesome
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« Reply #1 on: October 22, 2007, 07:32:17 PM »
which bolts are we talking about?
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gunny
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« Reply #2 on: October 22, 2007, 11:41:51 PM »
the 2 mounting bolts for the can
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« Reply #3 on: October 23, 2007, 09:11:03 AM »
Wait, there were two bolts holding my can?  When I changed to the White Bros. pipe, there was only one bolt on the can, and the clamp bolt was loose too!  Arrrrg!
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« Reply #4 on: October 23, 2007, 10:09:22 AM »
Or , if you dont want to do it your self, swing by your local dealership and have them do it ! It wont cost you anything ! And it allows the NTHSA to get thier number corrected.
Oh yeah, this recall applies for KL650-A16/L 2002- KL620E8F/L 2008 models but only a certian VIN ranges -
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« Reply #5 on: October 23, 2007, 02:37:24 PM »
There should be 2 bolts that hold the can to the frame.

The front one threads into the frame, and the rear one is a bolt * nut combo (I think).

For the WB can, it's the same. A bolt for each of the hangers.
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« Reply #6 on: October 23, 2007, 09:40:05 PM »
Yeah Hondo, the E2 came with two bolts for the can, but when I removed the right side cover, one of the bolts was missing from the stock can. 
Also, I had already tightened the clamp behind the rear brake reservoir (my girlfriend had to help me spell that damn word!) because it was LOOSE!  very mad
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« Reply #7 on: October 23, 2007, 10:30:14 PM »
the front bolt on my '02 was missing as well. Lots of lock tite later ..... it has managed to hang around.
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« Reply #8 on: October 23, 2007, 11:20:27 PM »
make that 18.5 ftlbs and as KLRKEN said, take it to your dealer so it can be documented as repaired. I think they have to report how many are fixed to the gov, maybe, not really sure.
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« Reply #9 on: October 24, 2007, 07:21:27 AM »
Bingo !  - as we do the recall and report them to Kawasaki, their NHTSA paperpusher makes reports showing what untis have been done and what ones havent , so, you can see the importance .
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« Reply #10 on: October 24, 2007, 08:30:57 PM »
4600 miles since 7/7/07 on my '08.  Going over my bike last month I found those bolts missing.  One was still sitting onthe muffler and I grabbed a replacement out of my stash.  The bolts along with a few quarts of oil and filters and one tire......no complaints here.

Rick
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« Reply #11 on: October 28, 2007, 07:21:57 PM »
So I got the recall notice in the mail.
What do I do, put the stock can back on, and take it to my local Kawi dealer for them to tighten the bolts, then come home to take it off again and put my E2 back on?  Sad
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« Reply #12 on: October 28, 2007, 08:08:14 PM »
well at least KHI is sending them out.
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« Reply #13 on: October 30, 2007, 09:30:11 AM »
Got my notice in the mail today.  I filed it away.  It is good they are sending out the notice but I'm not riding 50+ miles round trip for a bolt that I know is already tight.  Mine were not loose on either the 2007 or '08.  Ken
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« Reply #14 on: October 30, 2007, 09:56:35 AM »
Got my notice yesterday as well, already checked mine... the rear most bolt was not as tight as it should be.
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« Reply #15 on: November 17, 2007, 11:54:24 AM »
how do i start a post people
?
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« Reply #16 on: November 25, 2007, 03:27:23 PM »
Put on a new performance exhaust on the '08 yesterday.

Front bolt very loose, Back bolt mizzun.

Threadlock used. (What a difference even unjetted). Ride on!
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« Reply #17 on: November 30, 2007, 06:40:41 AM »
Which exhaust did you use?
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« Reply #18 on: November 30, 2007, 04:25:32 PM »
Quote from: Tipstall on November 30, 2007, 06:40:41 AM
Which exhaust did you use?
The E2, definitely puts out some thump when you spin the wrist under load. 96 decibels on a stand maybe. My wife agrees whole heartedly about the kick in the pants even 2-up @ 400lbs combined.
This sounds more like what I wanted too. High smile factor too...
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« Reply #19 on: March 03, 2008, 05:38:46 PM »
Hey all new to the site. Wonderin' I have seen a few blogs and such saying Kawi upgraded the doohickey for 08 can anybody confirm this for me? if not i'll drop the 100 for an eagle mfg
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« Reply #20 on: March 03, 2008, 07:27:22 PM »
It was redesigned and is not in immenant danger of breaking but the springs are too long so there is no adjustment happening when you loosen the adjustment bolt.  If there's some one near by that will loan you the tools then you can save yourself 60 bucks and just get the lever and springs.
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« Reply #21 on: March 04, 2008, 07:13:16 AM »
thanks again slo
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« Reply #22 on: April 24, 2008, 07:24:18 AM »
I just bought my first KLR650.  Its an 08.  What in the world is a "doohicky"?
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« Reply #23 on: April 24, 2008, 07:29:27 AM »
 Welcome wes31707!
It is the tensioner lever for the balancer chain. Do a search for doohickey and you have reading material for days.  WOW!
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« Reply #24 on: April 24, 2008, 09:29:43 AM »
wes31707 Welcome  Ehjoy the '08. I am having a great time with my blue one! What color?
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