Found this while doing some bike maintnence. I was probably riding like it for a while. I got lucky I didn't lose the muffler during a ride. Couple minutes with the welder and I was back in action though.

 

Close call eh. Simple fix and it's all good.

 

It's kinda funny, the only reason I took the side panel off was because I was thinking "maybe I should check the exhaust bolts to see if they're tight". The bolts were tight, it was just the mount that was loose.

My subframe is slightly bent on that side. If you look at my bike from the back, the rear fender is tweaked slightly(you can kinda see it in the pic if you look close). The mount didn't go back into place perfectly, I just pushed the muffler to where it was supposed to go and filled in the gap on the mount.

I should have really inspected it closer when I first noticed that the fender was tweaked. The springs that hold the muffler on are pretty strong, I really am lucky with the way I ride I didn't lose the muffler.

 

You'd notice it had fallen off pretty quickly although if it was on the slab it could have been rolled flat by a passing semi. Maintenance is the key.

 

man... that muzzy has taken a beating.....lol

 

When you remove the stock muffler, that side of the subframe/seat rail becomes weeker. Look at how the stock unit mounted and it becomes more clear.

I picked up this steet plate that fastens to the 3 stock muffler mounting points. I bought it from an Japanese aftermarket company that makes this specificaly for the KLX. It can easily be fabbed-up though. One of the original forum membes -I think maybe BMWHD- made one for his KLX. You can tell the difference immediately by doing a before/after lateral shake of the rear part of the seat...big difference.

 

The Muzzy isn't actually as bad as it looks. The rivited on name plate has taken most of the abuse. I wonder if I sent them a pic of it if they would send me a new one for free.

 

I remember you posting that a while back Dean. I was going to make one up and never got around to it, guess I should have. If you look where it is bent I am not sure if it would have really helped though.

 

LOL! Yeah, how did you get it to bend-up like that? On the other hand, maybe I shouldn't ask .

 

i had the same problem. i took a washer and had it welded to that piece you have there then welded back onto the subframe. i'd be shocked if it ever broke again.