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Hello, boys and girls, new here - first post - and pretty new to this crazy KLR world. I looked and didn't see anything about gutting the cat on my 2013. I ride with my wife and the heat for her right leg is unbearable. I hear richening up the mix help but what about killing the catalytic converter, surgically? My thought was to open it up, and bypass whatever is in there, straight to the muffler, then stitching her back up. I will do the .22 mod at the same time. Any thoughts? I'm writing from Venezuela so getting real aftermarket parts is difficult.

Thanks for the help,
Shawn
 

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I can only guess that the catalyzer is in the 1st half of the muffler.

No idea of how you might extract it or how much it would help.

But it would be easier to purchase a used 1987-2007 muffler. (Usually 'dirt-cheap'.) Guaranteed to fit. And shouldn't have to worry about a re-weld failing or internal parts rattling.
 

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Yep, just replace the muffler with an aftermarket unit or a stock pre-cat muffler. The cats were added mid to late 2010 so a 2008 - 2009 Gen2 muffler will work too.

...as an aside, my wife suffered a really bad burn due to contact with the cat area of the exhaust on my touring bike; they get VERY hot.

Cheers,
Dave
 

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Do all the KLR's from 2010 up have a Cat? Will removing it cause any problems with the bikes running/performance?
?1, '08-'10 mufflers $659.00 update to 2011 still $659.00 USD.
The 2012 and up muffler is $705.00 USD.
No way for me to confirm that any or none of them have Cats.

?2,
No. It definitely won't go any slower. Yet it probably won't go any faster either. vbg
 

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I cut the rear cap off removed the inner baffle real PITA but the whole thing eventually came out welded on a new cap with a 1.25 inch hole, installed pipe. Bike ran better, was louder needed re jetting got about 3 mpg less...probably cause the right wrist liked the sound.... And it was quite a bit cooler in that section as well. I have an early pipe with tweeter removed also don't know if it is cooler but the sound is better.

After a few months I wanted quiet again so off it went and on went a lexx muffler returned stock main 2.25 turns out on idle. .020 shim under needle and that's it. I average 54 MPG solo on cheap 87/10 gas. Gas hear has 10% ethanol in it.
 

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I'm thinking my '09 has a converter.

Previous replies have said no, but I developed a white spot on the front lower bulge
of the muffler, as well as one further back.

The holesaw/ de-baffle mod worked very well with or without a cat. To be fair I also
ran a piece of rebar in the front and hammered it in as far as it would go and twisted it
out with a pipe wrench. Punched thru two walls probably and one for sure. It was a flow
diverter or the cat. The flashlight didn't show much with the bend.
 

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?1, '08-'10 mufflers $659.00 update to 2011 still $659.00 USD.
The 2012 and up muffler is $705.00 USD..............
It is interesting that my parts fiches show the same part number for 2010 and 2011 #18091-0662, but $659.09 for the 2010 and $705.58 for the 2011. I have to wonder why the same part number has two prices.

The 2012 shows part number 18091-0826 for the same 705.58

2010: 2010 Kawasaki KLR650 (KL650EAF) Muffler(s)(EAF) | CyclePartsNation Kawasaki Parts Nation
2011: 2011 Kawasaki KLR650 (KL650EBF) Muffler(s) | CyclePartsNation Kawasaki Parts Nation
2012: 2012 Kawasaki KLR650 (KL650ECF) Muffler(s) | CyclePartsNation Kawasaki Parts Nation
 
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