Lexx Exhaust Repacking - KLR 650 

Some comments have been deleted by the poster. There was a few by a user "King Chilly", though he/her had a strange way of articulating him/her, self they did raise a couple of good questions. He challenged me that I said my first pipe discoloured due to jetting, and now I am changing my story to say its packing.. Well actually both are correct we believe. The bike was over fuelling at the time due to incorrect jetting done by the dealer, which caused the pipe to run a lot hotter than normal, we think??, fuel seemed to be burning into the pipe?? On the 6000kms ride I was doing at the time, it burned out or damaged the packing prematurely and caused the issue. It happened quickly, a lot quicker that this new one (with correct jetting) Well thats the best theory anyway. The supplier must have somewhat agreed it was unusual as they replaced it free of charge. So he was correct to a point. He/she has to realise we all work with the info at hand on the day. We learn as we go, and I do go and reshoot videos, but I do update video explanations from time to time. Hope this helps someone out. I just post stuff I do as I combine 2 hobbies, filming and exploring, and in a past life I was a Industrial Plant Mechanic. I dont really do it to get into arguments with anyone. But I do like to discuss anything I post, as I will also learn from this. There are some really smart people out there. Cheers All.

that has gone better than all my previous attempts to repack my Dr 125 back in the early 90's

When I first repack a muffler I do the first wrap with 434 stainless steel wool, and then put less of the fibreglass warp around that. It’s quieter, and the stainless wool protects the fibreglass insulation. Typically using stainless in the center gives you 4-6 times the life. There are specialist suppliers. Also worth considering replacing that inner tube with a perforated tube, also available. That’s one reason why it’s quite loud. I get the same flow with perforated, but quieter mufflers that last much longer. Sometimes they never need repacking again. Stainless and perforated tubes available here (and elsewhere): bestmufflers.com/bshop/index.php?id_product=2331&id_product_attribute=0&rewrite=car-motorcycle-muffler-packing-kit-high-quality-stainless-steel-wool-2mtrs-fibre-s2-&controller=product

Well done! At first I thought you were going to have a fit getting the roll back inside the pipe, but it went fairly smooth! Thanks for sharing, now I realize which pipe I, most likely, won't get!

Hey there JJ. Paul here in york pa. I'm a subscriber and fellow klr owner! I just wanted to say my 08 has a lexx exhaust also, I did the 22 cent mod then got the dyno jet kit. I also opened up the air box by drilling three one inch holes on top. This combo made an unbelievable difference! Lose maybe 6-7 mpg but much worth it! Love the vids!

here in 2023, excellent video

Hey mate, great video. That’s the reason I bought a Staintune exhaust. They have a steel wool type packing that never has to be replaced. The Staintune is welded up so even if I want to change the packing I couldn’t. On my videos the guy that rides with me is changing his packing in his big gun exhaust. When he went to buy the packing he saw you can buy a stainless steel wool. I’m assuming it would be like what’s in the Staintune exhaust. Maybe next time look at that Cheers Ken

Tks man for this info, slip on is cheap but need some works.I will go with Leovinci who does not need repacking.

Great vid. Is there a second baffle plate in the central tube or is it straight through ? (FMF Q series and some others have a baffle plate half way down and then just a spark arrestor at the end).

Should i repack the original KLR650 exhaust? Does the original has this problem?

So how long did you ride it for before you noticed it started changing color?

did I understand well? you mean to say that every 26 hours of use you have to change the packing?

Hey JJ. I really appreciate all of your videos, they've helped me get my klr running right. Do you remember how long the packing material used is? I bought a non lexx packing material and need to cut it to size, just not sure how long. Thanks man!

Hey Friend, I just bought an 05 660 Raptor and aftermarket exhaust and it's very loud. If the packing needs replacing and I do what you did here how much quieter can I expect it to be?

another great video, keep it going.

What is the best exhaust for the KLR 650?

Did your exhaust come already packed???

So what exactly happens if you just ignore the packing all together and never bother with it

Few thoughts.. if you get rid of the heat wrap on the head pipe the gasses will be cooler as they enter the muffler...longevity of the packing will be better.. Find the rockwool ( greenish color)packing, it tolerates the heat of a four stroke better.. that white stuff is Mostly for two strokes which have much cooler exhausts.. If you bike is running rich the raw fuel will soak the packing and break it down faster because it acts like a wick and burns rather than letting it evaporate. Make a pattern of holes in that core pipe and it will be deeper and mellower .. As Ronan said.. wrapping a layer of stainless mesh and then stainless wool if you can get it, then the higher temp stuff. Keep in mind the tighter the packing the less it absorbs sound.. more is not always better in this case. Like a gun suppressor, room to expand and slow down the gasses is more effective. I have a 2016 KLR 650 with the same exhaust.