Exhaust Heat - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 7 Old 06-04-2016, 12:10 PM Thread Starter
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Exhaust Heat

Is there an aftermarket exhaust that might be be cooler to the touch or cool enough to have soft bags closer than stock? Even with the metal shroud it still seems to give off too much heat for me to be comfortable with having a soft bag so close.

Maybe there is a mod that someone can suggest for stock? I would like to get aftermarket sometime.

'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
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post #2 of 7 Old 06-04-2016, 02:03 PM
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This calls for the support racks on the sides.

The distance keeps fresh air on the side cover preventing warpage too.

I dunno about any double walled mufflers on the market.

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post #3 of 7 Old 06-04-2016, 02:11 PM
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I run the KLR soft bags, no problems.
I don't know much about the racks, they came with the bike.
I did run stock muffler and lexx.
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post #4 of 7 Old 06-04-2016, 07:16 PM
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It seems that every time I read a ride report from someone with pannier side racks I wonder when they will be looking for a place with a welder. It almost always happens.

I use soft bags with no racks on 10,000 mile trips with no problems. I do insulate the exhaust and strap a piece of 1/2" pipe to it to keep the plastic off and allow room for air circulation. The insulation is covered with a sheet metal pipe support.

If you wrap the insulation around the tire side of the exhaust, when the suspension is fully compressed, the tire can hit it and jerk it off. 5.1 x 17 knobby tires can hit the muffler also, so I but several large washers between then muffler and the frame for a little extra room.

Before I did this I melted a tube in the bag. Now it works fine.
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post #5 of 7 Old 06-04-2016, 10:05 PM Thread Starter
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Quote:
Originally Posted by GoMotor View Post
It seems that every time I read a ride report from someone with pannier side racks I wonder when they will be looking for a place with a welder. It almost always happens.

I use soft bags with no racks on 10,000 mile trips with no problems. I do insulate the exhaust and strap a piece of 1/2" pipe to it to keep the plastic off and allow room for air circulation. The insulation is covered with a sheet metal pipe support.

If you wrap the insulation around the tire side of the exhaust, when the suspension is fully compressed, the tire can hit it and jerk it off. 5.1 x 17 knobby tires can hit the muffler also, so I but several large washers between then muffler and the frame for a little extra room.

Before I did this I melted a tube in the bag. Now it works fine.

Thats so fugly it's beautiful!
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'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s

Last edited by frostbitevinnie; 06-05-2016 at 08:40 AM.
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post #6 of 7 Old 06-04-2016, 11:00 PM
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I have a stock muffler and use the Wolfman Boulder Beta and never had an issue.

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2009 Kawasaki KLR 650

always tinkering!
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post #7 of 7 Old 06-07-2016, 09:01 PM
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Quote:
Originally Posted by gruet782 View Post
I run the KLR soft bags, no problems.
I don't know much about the racks, they came with the bike.
I did run stock muffler and lexx.
Those look like PMR racks. I have on the wife's KLR, Good for soft bags
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