Hot Right Side Case - Kawasaki KLR 650 Forum
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post #1 of 7 Old 04-30-2015, 09:43 PM Thread Starter
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Hot Right Side Case

I used my right side case for the first time and found that the back of the case was quite hot. Hot enough to make this side case pretty much unusable for many items. I have S-W Motech racks with MCM cases bolted directly to the rack.

Does anybody else have this problem? I haven't seen a single word on here for a problem like this. What to do? My first thought was adding some sort of heat reflecting material to the back side of the plastic case. I really don't want to be buying a new silencer, but doesn't the stock silencer have a catalytic converter in it? Would an aftermarket silencer run cooler?

Man, this sucks. I'm leaving on a trip in less than a week and wanted to take the
KLR. I might have to take my BMW instead. I wanted to save the BMW for a trip to Newfoundland (just put new tires on the BMW).
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post #2 of 7 Old 05-01-2015, 08:30 AM
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I hesitate to respond since I don't have the same setup as you. I have Caribou Cases racks and cases. I've not actually checked the temperature of the back of the right side case, but I can't recall it ever feeling very warm to the touch when taking the case off each night when I did my Alaska trip last year. Between the side panel that covers a good portion of the stock muffler and then the air that flows over the back of the case, I'm not sure how it could get all that hot.

When you noticed the problem, had the bike been running while sitting so that air wasn't going over the back of the case, or is the air blocked from flowing over the back of the case in some way?

I apologize for the basic questions. Your situation sounds odd.
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post #3 of 7 Old 05-01-2015, 07:21 PM
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I run through-over saddle bags with no rack/frame. The right bag would settle down so that it was touching the forward part of the muffler. It melted a strap and an inner tube in that area of the bag.

I got a 24"x24"x1/2" ceramic fire protection blanket for the back of 24x24 office building ceiling grill from an air conditioning contractor and used it to insulate the muffler. For the round part of the muffler I got a 6" diameter x 12" long sheet metal half pipe saddle from the same contractor. I turned the edges in 1/2" to hold it off the insulation and secured it with two large hose clamps. I also secured a 12" piece of 1/2' galvanized pipe on the outside of the sheet metal to hold the plastic side cover off the exhaust pipe and allow air flow between the plastic and the exhaust.

On the forward down turned section of the muffler I used tin snips to cut a couple of appropriately shaped pieces of sheet metal flashing from Lowe's and sandwiched the insulation between them with some small sheet metal screws. This shield is also held in place with large hose clamps.

This has worked for tens of thousands of miles on long distance dirt road routes and highways as well on two KLRs.

You can also get exhaust insulation at auto parts stores.
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post #4 of 7 Old 05-01-2015, 07:28 PM Thread Starter
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Quote:
Originally Posted by GoMotor View Post
I run through-over saddle bags with no rack/frame. The right bag would settle down so that it was touching the forward part of the muffler. It melted a strap and an inner tube in that area of the bag.
I got a 24"x24"x1/2" ceramic fire protection blanket for the back of 24x24 office building ceiling grill from an air conditioning contractor and used it to insulate the muffler. For the round part of the muffler I got a 6" diameter x 12" long sheet metal half pipe saddle from the same contractor. I turned the edges in 1/2" to hold it off the insulation and secured it with two large hose clamps. I also secured a 12" piece of 1/2' galvanized pipe on the outside of the sheet metal to hold the plastic side cover off the exhaust pipe and allow air flow between the plastic and the exhaust.
On the forward down turned section of the muffler I used tin snips to cut a couple of appropriately shaped pieces of sheet metal flashing from Lowe's and sandwiched the insulation between them with some small sheet metal screws. This shield is also held in place with large hose clamps.
This has worked for tens of thousands of miles on long distance dirt road routes and highways as well on two KLRs.
You can also get exhaust insulation at auto parts stores.
That blanket would work good on the inside of the case. I will check the auto parts store tomorrow to check out the insulation that you mention or whatever else they may have. Thanks.
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post #5 of 7 Old 05-02-2015, 09:18 AM
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That's the primary reason I installed the Lexx muffler. Even after a short ride in chilly weather I couldn't even hold on to the blinker. I didn't want my kids leg or hand to accidently touch anywhere close to the muffler.
Installing the inexpensive Lexx saved weight, sounds nice, not too loud, and reduced a lot of heat.

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post #6 of 7 Old 05-02-2015, 12:15 PM Thread Starter
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That's the primary reason I installed the Lexx muffler. Even after a short ride in chilly weather I couldn't even hold on to the blinker. I didn't want my kids leg or hand to accidently touch anywhere close to the muffler.
Installing the inexpensive Lexx saved weight, sounds nice, not too loud, and reduced a lot of heat.
Never heard of a leg muffler. Looked it up online, just $199.99 at Rocky Mountain.

How did it reduce heat for you? What was less hot?
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post #7 of 7 Old 05-02-2015, 12:52 PM
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The stock muffler is a freakin stovepipe. You could cook your food on it while out camping. The Lexx muffler gets hot like a normal muffler will, but you can hold your hand on everything around it. You might be able to get it a little cheaper on ebay, but Lexx is Rockymtns brand.

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