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High mounted exhaust - how to pack!? High mounted exhaust - how to pack!?
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Equipping the Bike - what's the best gear? Anything to do with the bikes equipment, saddlebags, etc. Questions on repairs and maintenance of the bike itself belong in the Brand Specific Tech Forums.
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  #1  
Old 23 Aug 2008
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High mounted exhaust - how to pack!?
Hi all,

First post on this forum!! Bought a Suzuki Djebel 250cc yesterday and I really like the bike, but... it has a high mounted exhaust that is exposed. The bike has a nice rack on the back, but if I hang saddlebags over them, the right bag will hang on the exhaust. Exhaust gets pretty hot and I am afraid it will burn the bag.

What is your advice? My plan is to go traveling with the bike, so need to take camping gear and the whole lot.

Thanks,
Richard
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Old 23 Aug 2008
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I have a DR650 and solved the problem by installing a Supertrapp exhaust down low. Got a local co. in France to make a stainless pipe to join onto the header pipe.

If you don't want to do that and you want to use soft luggage then you need to have a small rack made to keep the bag away from the exhaust. Not only will it burn you bag, if there is a plastic sidecover over it it too will be melted. While you are at it I would recommend the same for the other side.
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Old 23 Aug 2008
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I had the same bike in 2002.
Superb performer, great offroad and onroad. Longrange tank, wish I still had it.
I did Osaka to Barcelona on it in 7months over all kinds of terrain with homemade soft pannier bags on mine.
I didnt have any frames made up to keep the bags off but in hindsight I should have.
I wrapped the exhaust in asbestos-like insulation I bought at a bikestore in Japan.
The plastic cowling lasted until about Mongolia but the bag didnt burn.
It wasnt until Barcelona when Id picked up a passenger and we were heading south to Maalaga that complete disaster struck.
The bags were pushed further back to allow the pillion to use the pegs, this created a firery end to my trip. We were speeding down the highway when a car pulled up next to us and the driver was gesturing with his hands to stop. We stopped and the bag burst into flames. Luckily that side only had my clothes and food, not my camping gear.
I would get a frame made up or make up a simple one yourself. Remove the plastic cowling and bend up some 1.5-2mm aluminium sheet to fit.
I also found the bags I made were too deep and brushed up against the rear sprocket when the suspention was under load. Keepp this in mind.

Enjoy the bike, Im envious.
Nathan
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Old 23 Aug 2008
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Quote:
Originally Posted by AussieNat View Post
or make up a simple one yourself. Remove the plastic cowling and bend up some 1.5-2mm aluminium sheet to fit.

That's exactly what I'm going to try with my CRF450X to mount soft panniers. I'm going to add some heat shield insulation material to the underside of the aluminium for added refinement. If it works well, I'll post some pics.
Stephan
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Old 24 Aug 2008
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Originally Posted by AussieNat View Post
I would get a frame made up or make up a simple one yourself. Remove the plastic cowling and bend up some 1.5-2mm aluminium sheet to fit.
I also found the bags I made were too deep and brushed up against the rear sprocket when the suspention was under load. Keepp this in mind.
I was thinking of making something with wood, but it wouldn't be very classy and it might rattle and damage the paintwork. I don't really understand what you are saying though... 'plastic cowling' is that the little faring that is covering the first bit of the exhaust before it comes exposed? Could you be a bit more graphical on the aluminium sheet, where it goes from and to and how to attach?

I am a total noob, just got my learners and want to get in the overlanders motorbiking stuff. Last year I finished a trip from Prudhoe Bay, Alaska to Yaviza, Panama with a 1986 Subaru GL (450.000 km on the car!) and I noticed how the motorbike travelers always seem to bond instantly. So I thought I have to give that a try as well. Now New Zealand is going to be a testcase for that.

Everybody thanks for the input!
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Old 24 Aug 2008
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Sorry, not very desciptive.

Wood doesnt sound like the right material for this job IMO.
I have seen it done mind, but only in Asia!!!
Yes by cowling, I mean the plastic faring that covers part of the exhaust.

I cant recall the layout or mounting points for this cowling but you could use the same mounting points to secure your handmade Aluminium shield.

Its best to just play around and experiment yourself, youll be surprised what can be done in just a couple of hours.

You need at least 2 mounting points.
Cut up some cardboard trace the mount points you want to use and see what looks the best. Then if you are really cautious get some thin tin sheet and make a mock up before cutting and bending up your aluminium.

Its important that your new shield doesnt touch the hot exhaust anywhere as youll end up with the same problem you are trying to avoid. I would leave about 2cm gap so air can easily pass through.
Another important point is to keep all corners round and edges blunt to avoid injury should you come off the bike.

Give it a go.
Bike touring is comradeship for sure but its a whole lot more too.
Just get out there.
N
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