So we were up till about midnight last night putting an FMF jet kit and HMF exhaust on FROG last night.

If anyone is considering this mod I highly recccomend HMF Engineering. Thier quality is top notch, tech support is awsome and the price is the best I've found.
Here's a link to thier how to write up on the install.

http://www.hmfengineering.com/forums/showthread.php?t=1617

Definitly a bit scary to completely disassemble a bike and assume you'll get all the bolts back in the right place and not forget anything.
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Lots of pictures help.
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I ended up using a 132 main jet and 35 piolt with 2 3/4 truns out on the idle jet. FMF jets are labeled different then Dyno jets. 132 is for sea level to 3K feet.

Carb out, rag in intake and disconnected hoses everywhere.
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Just about done.
Tighten exhaust bolts. Fix float bowl leak, replace punctured fuel line. Find out where the heck the clear hose goes. Crack cold beer.
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Finally. Fires up without choke, no leaks. Nice low thump at 1,400 RPM idle. Too loud to rap up at midnight on Tuesday.

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On my KLR 650, I deleted a rubber "snorkel" piece in the intake throat, drilled out the cap over the air screw and reset it and opened up the hole in the slide with a drill bit. Got all the tips from a board I visit specific to Kawasaki dual sports.

I also added a Mercedes Benz supercharger check valve to the crankcase breather line so air can only be pumped out (one-way valve) so it's not pumping air back and forth. That results in power loss from the pumping action under the big cylinder.

I also tee'd my carb breather line so there's less chance of ingesting water during stream crossings. Stock, it just ran under the seat; now it tees off from there and goes back by the rear wheel as well.

I'm not going to re-pipe my exhaust. I like mine quiet, plus there's little to be gained on this particular engine in terms of power. The first mods I listed in this post are for throttle response, mostly. Unrestricting the intake made it louder, though.

Mods are fun!

John B.

I'm getting a pretty good pop-pop-BANG on decel from 6,000 RPM.

I think I need to get the pipe seated a bit furtehr into the header, I can feel exhaust puffing out of the fitting where the slots for the exhaust clamp are.

Might need to put the airbox lid back on and just remove the snorkle if that doesn't fix it.

Do have a one way valve and little baby K&N on the crank breather hose tucked up high under the seat.



Your right about that HMF pipe, it is pretty dang loud at WOT. Might put the quiet core insert in there for riding in town.