crazy rusting on muffler after only 15000km - Kawasaki Versys Forum
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post #1 of 11 (permalink) Old 07-29-2016, 07:53 PM Thread Starter
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crazy rusting on muffler after only 15000km

hi,

i have a puddle of water under my versys '15.
It is merely 15'000km.

Day 1 is a tea spoon, day 2 a dice, and shrinking until dripping only 1 2 drops after 5 days. This is while staying in the garage.
And the last day I rode was dry.

As if there was water in the muffler.
But it is coming from everywhere around the muffler!!!
brown wet spots,
green wet spots,
wet crud that seems to never dry.

see pictures.
I've NEVER seen that in 124'000km on my previous ninja 650r.

WHAT IS GOING ON?







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post #2 of 11 (permalink) Old 07-29-2016, 08:34 PM
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Is the weep hole at rear bottom of muffler clogged up?
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post #3 of 11 (permalink) Old 07-29-2016, 08:49 PM Thread Starter
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Is the weep hole at rear bottom of muffler clogged up?
I did check that and I don`t think so. I mean, It not like I can insert very far. There was some dirt of course, but I wouldn`t call it clogged, and for all these days it have not dripped from there.

It`s like if someone had been spraying some corrosive spray/water all over every day...(of course impossible, it's in the closed garage) All I ever did is clean my chain on the other side and I always use a cardboard to protect the muffler. Besides, That stuff would evaporate quickly and certainly smell, nothing like water.
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post #4 of 11 (permalink) Old 07-29-2016, 09:47 PM
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Muffler must be full of water if it keeps dripping... Can you blow compressed air in the hole, or maybe run a steel wire in it?
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post #5 of 11 (permalink) Old 07-30-2016, 06:23 AM Thread Starter
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little whole is not clogged.

but that wouldn't explain:
a) why it rusts all around
b) why a motorcycle muffler rusts (never seen that before on my previous kawa)
c) why it happened so suddenly in 4 month of owning it, I bought it new.
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post #6 of 11 (permalink) Old 07-30-2016, 08:24 AM
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Originally Posted by dddd View Post
little whole is not clogged.

but that wouldn't explain:
a) why it rusts all around
b) why a motorcycle muffler rusts (never seen that before on my previous kawa)
c) why it happened so suddenly in 4 month of owning it, I bought it new.
have you checked the condition of your sealed lead/acid battery, maybe it's no longer sealed. the battery box drains are above this general area.
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post #7 of 11 (permalink) Old 07-30-2016, 01:56 PM
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After a 19 day ride on MY '15, MOST days in rain, NO rust on mine (just the 'baked-on' WD40 I use to clean/lube my chain).

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post #8 of 11 (permalink) Old 07-30-2016, 02:05 PM Thread Starter
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have you checked the condition of your sealed lead/acid battery, maybe it's no longer sealed. the battery box drains are above this general area.
I though about that. Would have explained well the heavy corrosion.
But the bottom of the compartment is dry, and I would likely have seen dammage on the floor, where it is dripping where I have those 1/4 inch foam 2'x2' tiles. Besides having touched it with my fingers...

I also suspected the tank overflow to be badly routed but no. And the smell alone would have given it up.

The rear brake fluid is not low, besides the liquid would have been viscous and oily. Not that either.

Prestone would be green of course.

It's pretty much water, afaict.

So, to re-ask a question: isn't the muffler supposed to be stainless steel?
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post #9 of 11 (permalink) Old 07-30-2016, 02:32 PM
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It's not high grade stainless steel. It is likely 403 SS, as used on car exhausts... Is it very humid, or dripping from ceiling in your garage?
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post #10 of 11 (permalink) Old 07-30-2016, 03:13 PM
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You could also remove the muffler to determine how flooded it may be.
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post #11 of 11 (permalink) Old 07-30-2016, 05:26 PM
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I rode my V650 through deep water (18" or so) numerous times a few weeks ago, with nary a bit of rust as the result. I even parked it one time with some of the exhaust system in shallow water until we could drag it out.

With the rust on the outside of your muffler it doesn't seem that water inside the muffler is the problem. Condensation?

I'm wondering if you've ridden through some leftover salt on the roads from last winter. Maybe a puddle somewhere that splashed up on the muffler and then the salt dried onto the surface.

It seems unlikely to me that the muffler would corrode like that without some chemical assistance besides just plain H2O.
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