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I WOULD LIKE TO START BY SAYING I AM AN OLD SCHOOL KLR 650 CULT TYPE. IF YOU HAVE EVER KNOWN ANY ,WE DON'T VERY OFTEN THROW $ AT IMPROVEMENTS TO OUR MACHINES, WE MOD THEM AND HAVE FUN DOING THEM.
RECENTLY I WAS CONCIDERING A PERFORMANCE KIT,-PIPE- INTAKE CLEANER-JET KIT~$300.
STARTED AT THE OEM FILTER,LOTS OF NON-BREATHING SCREEN HOLE MATERIAL. TOOK MY DREAMEL AND CUT AWAY ALL THE SCREEN FROM THE FRONT METAL SLEAVE AND FLANGE BACK , INCLUDING THE BACK FLANGE THAT HANGS IN THE PLASTIC HOLDER. SLIPPED THE FRONT PART OF THE BASKET WHICH NOW ONLY CONSISTS OF SLEAVE AND METAL FLANGE BACK INTO FILTER AND CLAMPED BACK ON RUBBER ADAPTER. I DID PUT A SEALING BOLT IN THE BACK HOLE OF FILTER TO USE AS A HANGING TIT LIKE WAS ON BACK OF METAL REAR FLANGE.USED A NYLA-NUT ON THE INSIDE.WA-LA AN OPEN BREATHING AIR CLEANER WITH LOTS OF BREATHING CAPACITY.
NEXT CAME THE OEM MUFFLER, GOOD STAINLESS, JUST NEEDS TO BE FREER FLOWING.I REMOVED THE END BAFFLE PLATE ,AGAIN USING MY DREAMEL AND A BUDDIES DIE GRINDER, GUTTED ALL BUT THE SPARK ARRESTER AND SET IT ASIDE.NEXT I GOT A 1" HOLE SAW AND DRILLED A HOLE JUST TO THE LEFT OF EXISTING HOLE IN THE INSIDE CHAMBER. IF YOU LOOK WITH A FASHLIGHT YOU CAN SEE THE TOURTUROUS PATH THE GAS HAD TO FOLLOW TO EXIT. I HAD SOME GLASS WOOL SO I MADE A WRAP ON THE INSIDE CHAMBER AND COVERED THE INSULATION WITH SOME STAINLESS HARDWARE CLOTH I HAD AQUIRED SOMEWHERE.
,TO KEEP THE WOOL IN PLACE AS NOT TO ALLOW THE WOOL TO SLIP AND COVER THE GAS EXITING HOLES.THE GLASS WOOL WAS ADDED JUST TO HELP QUITE SOME OF THE LOUDNESS.
ALMOST THERE.........
NEXT CAME THE CARB.REMOVED THE TOP COVER,CUT THE SLIDE SPRING,WHICH HAS BEEN DISCUSED MANY TIMES HERE ON THE SITE. I NEXT REMOVED THE NEEDLE HOLDER,USED AN OVERSIZED DRILL BIT,JUST SLIGHTLY,AND REAMED THE HOUSING HOLE WHERE THE NEEDLE RUNS UP AND DOWN.THE LAST THING I DID WAS PUT ANOTHER FLAT WASHER, ABOUT THE SAME THICKNESS AS THE EXISTING ONE UNDER THE OEM WASHER.WHAT THIS DOES IS HOLD THE NEEDLE UP JUST A LITTLE OUT OF THE MAIN JET ALLOWING MORE FUEL THROUGHOUT THE POWER BAND. AIR AND FUEL IS THE NAME OF THE GAME,SIMPLY! AFTER BUTTONING ALL BACK TOGETHER,USE THE AIR/FUEL MIXTURE SCREW TO DIAL IT IN ,KEEPING AN EYE ON WHAT YOUR PLUG IS DOING AND THE FEEL IN YOUR PANTS.
FOR A POOR MAN'S PERFORMANCE FIX I WAS VERY PLEASED,YOU CAN DEFFINITLY FEEL THE DIFFERENCE.THE ONLY UNDESIREABLE WAS THE LOUDNESS OF THE MUFFLER,I ADDED A 5" STAINLESS 2 1/2" O.D. EXTENTION TO GET THE NOISE BACK JUST A LITTLE.
WE OUR AT ABOUT 5000 FT. ELEVATION HERE AND I RUN 27" MAXXIS-BIG HORNS. THE MOD IS VERY GOOD ON GAS AS WELL,WHAT A BLAST!



PIPESTONE
 

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I have done all these mods as well. To be perfectly honest I didn't notice a difference...................................positive or negative. I am not bashing, just throwing my .02 worth in . Keep on keepin' on
 
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