Catalytic Converter - Gen 2 - 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 23 Old 03-16-2010, 12:33 AM Thread Starter
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Catalytic Converter - Gen 2

Yesterday it was brought to the attention of many of us that the 2008 to current KLRs have a catalytic converters.

What do you know about the KLR catalytic converter?

How will Air / Fuel / Exhaust mods effect the KLR catalytic converters?

I know very little about the KLR catalytic converter so please share what you know or ask your questions.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #2 of 23 Old 03-16-2010, 05:52 AM
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I found out you have to remove the Clean Air System Vacuum Switch (Octopus) and cap all three lines when you install an aftermarket exhaust or you will get backfires.

Two Brothers muffler, Dyno jet carb mod, HT PD nerf bars/w EG-3 and skid plate, HT OSR side racks, Eagle fork brace, TPI comfort flat seat, HT center stand, rear master cylinder guard, Thermo-Bob, Fieldshear saddlebags, T-bags Helmet bag as top box.
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post #3 of 23 Old 03-16-2010, 10:15 AM
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One unfortunate side effect is that using an exhaust sniffer to determine AFR on a stock exhaust won't work! Gotta have a bung in the header.

Also, I would think that if you run rich you stand a chance of clogging the cat, unless the air injection can keep things hot enough to keep it clean. Also, removing the air injection with a stock muffler seems like a bad idea, as the cat might clog after a while.
Speaking of removing that, I'd encourage anyone contemplating that change not to do it by cutting and crimping the line. You can't go back without $$. Make a blanking plate out of some 1/8 or 3/16" plate.

Tom

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post #4 of 23 Old 03-17-2010, 10:15 PM
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I just pulled all the hoses off the pump. Found a bolt that would thread into the rubber hose. Put a zip tie around the hose and bolt for good measure and then zip tied the hoses up out of the way and put the pump away on the shelf in case it ever has to be put back on.

2005 Red one
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post #5 of 23 Old 03-17-2010, 10:37 PM Thread Starter
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Tom, do you have the specs on the 50 States and 49 States Gen2 KLRs?

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #6 of 23 Old 03-17-2010, 11:14 PM
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Quote:
Originally Posted by tomatocity View Post
Tom, do you have the specs on the 50 States and 49 States Gen2 KLRs?
Tim -

The only thing I have is that the book shows the cat muffler for "U.S.A." and for "U.S.A. (CALIF") and "CANADA", so I think all the Gen2 have a cat. The only one that looked like it wasn't a cat was Australia.

The cat muffler part number is 18091-0465, and the non-cat is 18091-0328. There is supposed to be a marking on the muffler body on the inboard side of the aft mounting flange. I'd look at mine right now, but it in the rafters and the wife's car is in the way.

The page doesn't show any real procedural info, just pictures. Do you think it would be a copyright violation to post up an image of the page? If we're comfortable with that, I'd do it.

Tom

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“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 03-17-2010 at 11:19 PM.
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post #7 of 23 Old 03-17-2010, 11:30 PM
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Ok, now, this is from the front of the book under the heading "Emission Control Information". It is slightly contradictory to what is in Section 5-6, which I quoted above.

"2. Exhaust Emission Control System
This system reduced the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. the fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of the model motorcycle manufactured primarily for sale in California includes a catalytic converter system."

I added that emphasis. So, the above says cats in California models, while Section 5-6says cats in all of US and Canada.

Tom

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #8 of 23 Old 03-17-2010, 11:41 PM Thread Starter
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Quote:
Originally Posted by Tom Schmitz View Post
Ok, now, this is from the front of the book under the heading "Emission Control Information". It is slightly contradictory to what is in Section 5-6, which I quoted above.

"2. Exhaust Emission Control System
This system reduced the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. the fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of the model motorcycle manufactured primarily for sale in California includes a catalytic converter system."

I added that emphasis. So, the above says cats in California models, while Section 5-6says cats in all of US and Canada.

Tom
That is a lot to digest. How about the rest of the emissions like the carbon cannister? What I am trying to find out is what is good for the Gen2 owners. What can they do for longevity. Should they buy a Gen1 muffler and put the catalytic muffler on the shelf until needed? I don't know.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #9 of 23 Old 03-18-2010, 12:12 AM
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Quote:
Originally Posted by tomatocity View Post
That is a lot to digest. How about the rest of the emissions like the carbon cannister? What I am trying to find out is what is good for the Gen2 owners. What can they do for longevity. Should they buy a Gen1 muffler and put the catalytic muffler on the shelf until needed? I don't know.
Tim-

There isn't much in the book. The first page lists
1) Crankcase Emission Control System
2) Exhaust Emission Control System
3) Evaporative Emission Control System

In Section 3-6 has a pictograph of the Evap System.

I don't see any specs anywhere or any other info in the book.

Somewhere in the Code of Federal Regulations I ran across a blurb that says that motorcycles after 2003 were supposed to have an emissions label on them, but I haven't found a label on mine yet (I haven't looked real hard yet, either) but it may say no more than "his motorcycle conforms to all the crappola that was in effect as of the date of manufacture"...

Tom

Tom

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #10 of 23 Old 03-18-2010, 12:39 AM
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This is interesting...
Attached Files
File Type: pdf kawasaki_m0010484_651_0d8_hn.pdf (54.6 KB, 58 views)
File Type: pdf kawasaki_m0010455_651_0d8_hn.pdf (56.0 KB, 34 views)

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 03-18-2010 at 12:54 AM.
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