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Comparisons

This is a comparison shot of the Stock & XCR exhaust systems side by side.

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I then weighed each system on a digital scale.

The Stock exhaust weighed in at 10 lbs, 13.4 ozs-

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Then I weighed the XCR, which weighed in at 5 lbs, 1.4 ozs.

That's 5 lbs, 12 ozs less than stock!

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This kind of weight savings is big news on any motorcyle, as it's not easy to shave off 5+ pounds.

 

Installation

Installation of the XCR on my 2001 KLR650 was relatively straitforward. I first removed the 2 screws that hold the right side cover on, and then the side cover itself.


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Then I removed the rear brake master cylinder cover to gain access to the clamp holding the exhaust can to the header pipe and loosened the clamp as shown below-


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I used a metric allen head socket & wrench -


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Then I loosened the two (2) bolts that hold the exhaust to the frame-

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The exhaust slipped right off.

Installation is a reverse of removal, with a few differences.

The first difference is that the XCR does not require a clamp to hold it to the exhaust header. It is a true "slip on" system designed to fit the stock KLR650 head pipe precisely.

Here's a photo of the overlapping slip-on joint - nice fit!

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Here's the rear mounting bolt and standoff. The solid aluminum standoff & steel bolt are a perfect fit. Blue threadlocker is recommended on both bolts.

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To finish the installation I reinstalled the right side cover.

Here are a few photos of the completed installation. Note that the carbon on the rear fender was from the previously installed stock exhaust.

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