Location of Catalytic Converter - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 5 Old 10-04-2019, 01:26 PM Thread Starter
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Join Date: Sep 2019
Location: Rockland County, NY
Posts: 31
Location of Catalytic Converter

I looked in the owners manual (pg 58) and was only able to see that there is a converter in the exhaust. It is not clear where though. Does anyone know where in the stock exhaust on a 14.5 the cat is located (head pipe, muffler, ...)?

Thanks in advance
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post #2 of 5 Old 10-04-2019, 03:31 PM
Join Date: Nov 2009
Location: Lander, Wyoming
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It is inside of the muffler not the header pipe.

But I do not know in which portion of the muffler, I just assume that it is probably in the forward portion where it will get hot the quickest.
Don't know what it looks like either.

If you wish to reduce side panel heat, but don't like LOUD exhaust, purchase a used '87 - '07 possibly even thru '09 OEM muffler.
They do not have the catalyst in them.
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 5 Old 10-10-2019, 06:32 AM
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Join Date: Sep 2017
Location: Adelaide, South Australia
Posts: 86
Hello people

The catalytic converter is usually some mesh looking stuff that is coated with materials that catalyze a chemical reaction within the muffler. I learned about catalytic converters in high school chemistry. I am 49 years of age now, so I remember very little about how they work.

This is a video of a cut open KLR650 muffler :
you can see the creator of the video has cut through some mesh. I think the mesh is the converter, or perhaps the perforated walls that can be seen between the chambers.



Last edited by timberfoot; 10-10-2019 at 06:42 AM.
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post #4 of 5 Old 10-10-2019, 11:38 AM
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Join Date: Aug 2010
Location: Kelowna, B.C.
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I don't see anything resembling a cat in that video, but then we don't know what year that muffler is..... It certainly isn't the perforated metal. I'm always amazed the the stock muffler performs as well as it does given the construction of it.....amazing.

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post #5 of 5 Old 10-10-2019, 11:39 AM
Join Date: Nov 2009
Location: Lander, Wyoming
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There may be several internal differences of the KLR650 muffler "guts" between different years and specifically different countries. I do not see anything in the video muffler that suggests to being a catalyser.

The rearward most chamber of my 1987 is about equal in length to that mufflers two rear chambers. My 87 tail outlet did not have the "WWII German Tatter Masher" hand gernade appearance, but was more like a 1.5" OD, 5.5" long, 0.625" ID miniature glass pac muffler for its full length. There is a 'Krizman' spiral diffuser, spark arrestor immediately ahead of the 'mini glass pac', at about the location of his 3rd from last partition wall. The 0.625" ID inner pipe of the 5.5" mini glass pac is perforated, its full internal length.
My brothers 2009 Gen 2 muffler has the same tail chamber design as my '87.

The 5.5" mini glass pac was/is not so affectionately know as the "Tweety" by some owners. Due to a gap in the weldment of either the perforated core or the outer casing, some of them would 'chirp' annoyingly at low rpms. So many of them either had chisels or screwdrivers hammered thru them or hole-sawed completely out of the tail end cap. (Mine rusted off inside of the tail end cap, so was hole-sawed out.)
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