backup reserve/ gps

[david.r.nichols@sbcglobal.net]

Here is a photo of what looks like a hole in the bottom of my air box. Its looking forward right above the exhaust clamp that joins the head pipe to the muffler. If it is a hole, its on the carb side of the filter. Has my exhaust melted a hole? http://www.flickr.com/photos/9992563@N08/6180932301/

[Eddie]

It looks like a hole. Can you put your finger through it? Another check: Remove the air filter cover and air filter. Dim the lights in your work area and shine a small flashlight down the area normally occupied by the filter. If it's a hole, light will be visible on the outside. eddie

> [Original Message] > From: david.r.nichols@... > To: DSN_KLR650@yahoogroups.com> > Date: 9/25/2011 10:35:48 AM > Subject: [DSN_KLR650] Hole in my air box? > > Here is a photo of what looks like a hole in the bottom of my air box.

Its looking forward right above the exhaust clamp that joins the head pipe to the muffler. If it is a hole, its on the carb side of the filter. Has my exhaust melted a hole?

> > http://www.flickr.com/photos/9992563@N08/6180932301/ >

[David Nichols]

Yes, it is a hole. I stuck a piece of wire thru it and I could see the wire thru the filter side. My question now is, why did Kawasaki locate the exhaust so close to the plastic air box, and has anyone else ever had this problem before? Not knowing how long its been this way (I'm not the original owner), I'm wondering how much damage has been done with the unfiltered air that's been getting in. This bike has just under 13,000 miles. Maybe everybody should check their air boxes... [Non-text portions of this message have been removed]

[KLRDON]

I'll bet you have a exhaust leak that was shooting hot gas up there to melt that hole. Seem like a similar phenom was discussed here or on Advrider, cannot remember where exactly. Don M

On 9/25/2011 10:35 AM, david.r.nichols@... wrote: > Here is a photo of what looks like a hole in the bottom of my air box. Its looking forward right above the exhaust clamp that joins the head pipe to the muffler. If it is a hole, its on the carb side of the filter. Has my exhaust melted a hole? > > http://www.flickr.com/photos/9992563@N08/6180932301/ > > > > ------------------------------------ > > List Sponsors - Dual Sport News: http://www.dualsportnews.com > Arrowhead Motorsports: http://www.arrowheadmotorsports.com > List FAQ courtesy of Chris Krok: http://www.bigcee.com/klr650faq.html > Member Map: http://groups.yahoo.com/group/DSN_KLR650/app/peoplemap/view/map > Group Apps: http://groups.yahoo.com/group/DSN_KLR650/grouplets/subscriptionsYahoo! Groups Links > > > >

[James Douglas]

Duct tape that hole closed and call it a day, and check it in a month or so? Sorry,go with the cheap!

> > I'll bet you have a exhaust leak that was shooting hot gas up there to > melt that hole. Seem like a similar phenom was discussed here or on > Advrider, cannot remember where exactly. > > Don M > > On 9/25/2011 10:35 AM, david.r.nichols@... > wrote: > > Here is a photo of what looks like a hole in the bottom of my air > box. Its looking forward right above the exhaust clamp that joins the > head pipe to the muffler. If it is a hole, its on the carb side of the > filter. Has my exhaust melted a hole? > > > > http://www.flickr.com/photos/9992563@N08/6180932301/ > > > > > > > > ------------------------------------ > > > > List Sponsors - Dual Sport News: http://www.dualsportnews.com > > Arrowhead Motorsports: http://www.arrowheadmotorsports.com > > List FAQ courtesy of Chris Krok: http://www.bigcee.com/klr650faq.html > > Member Map: > http://groups.yahoo.com/group/DSN_KLR650/app/peoplemap/view/map > > Group Apps: > http://groups.yahoo.com/group/DSN_KLR650/grouplets/subscriptionsYahoo! > Groups Links > > > > > > > > > >

[Non-text portions of this message have been removed]

[Eddie]

Depending upon how large of a hole you have, I say fashion a "patch" made of thin aluminum sheet and "glue" it in place with some oil/gasoline safe sealant and maybe a couple of self-tapping sheet metal screws or rivets. The hole would be patched permanently and the aluminum would deal with the heat issue or how it came to be. (poorly fitted exhaust? Hole rusted in the pipe?) This doesn't address the question of what else got in the hole while riding the bike? But, if it's a small consolation, the bottom of most airboxes is a tad oily. The oil would trap some of the gunk. You'd know soon enough if you decide to spray the airbox clean with brake cleaner,etc...prior to gluing on a "patch". It'd wash out the stuff. Good luck! eddie

[spike55_bmw]

I'd go with an exhaust leak too. The that's right above the transition point between exhaust header and muffler. Did the PO run an aftermarket muffler? Are you? It may not have been a good fit. I know that there was a recall (Pre '08 models) to tighten / replace any missing bolts (two) that holds the OEM muffler in place. A lose muffler may have allowed a leak. Do you see any filler material sealing the gap between the header and muffler? Even if you seal the airbox, a continuous stream of hot gases coming from a leak may cut it open again. I'd pull the muffler and make sure it has the ability to seal itself on that header. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > Yes, it is a hole. I stuck a piece of wire thru it and I could see the wire thru the filter side. My question now is, why did Kawasaki locate the exhaust so close to the plastic air box, and has anyone else ever had this problem before? Not knowing how long its been this way (I'm not the original owner), I'm wondering how much damage has been done with the unfiltered air that's been getting in. This bike has just under 13,000 miles. Maybe everybody should check their air boxes... > > > > [Non-text portions of this message have been removed] >

[David Nichols]

The hole is forward of the exhaust joint but I can see how an exhaust leak could cause it. Because the muffler side slips over the header side the gases would be directed forward. The muffler is now off the bike, that's how I discovered this. I will make sure it seals when I put it back on. I'm planning on heat tile on the air box and insulating wrap around the pipe. I think I will repair the hole and just keep an eye on it. Can I get ideas on what to use to plug the hole? I know I can score an Ebay air box for $30... ________________________________ From: spike55_bmw To: DSN_KLR650@yahoogroups.com Sent: Sunday, September 25, 2011 4:57 PM Subject: Re: [DSN_KLR650] Hole in my air box? I'd go with an exhaust leak too. The that's right above the transition point between exhaust header and muffler. Did the PO run an aftermarket muffler? Are you? It may not have been a good fit. I know that there was a recall (Pre '08 models) to tighten / replace any missing bolts (two) that holds the OEM muffler in place. A lose muffler may have allowed a leak. Do you see any filler material sealing the gap between the header and muffler? Even if you seal the airbox, a continuous stream of hot gases coming from a leak may cut it open again. I'd pull the muffler and make sure it has the ability to seal itself on that header. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > Yes, it is a hole. I stuck a piece of wire thru it and I could see the wire thru the filter side. My question now is, why did Kawasaki locate the exhaust so close to the plastic air box, and has anyone else ever had this problem before? Not knowing how long its been this way (I'm not the original owner), I'm wondering how much damage has been done with the unfiltered air that's been getting in. This bike has just under 13,000 miles. Maybe everybody should check their air boxes... > > > > [Non-text portions of this message have been removed] > [Non-text portions of this message have been removed]

[spike55_bmw]

The unsealed hole wouldn't be a problem as long as you don't get into deep water and the foam filter is still intact. I wouldn't get too hung-up on replacing the airbox. Use small bolt & nut / a fender washer on each side of the hole / silicone sandwiched in between. That would seal it for years and out of sight, out of mind. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > The hole is forward of the exhaust joint but I can see how an exhaust leak could cause it. Because the muffler side slips over the header side the gases would be directed forward. The muffler is now off the bike, that's how I discovered this. I will make sure it seals when I put it back on. I'm planning on heat tile on the air box and insulating wrap around the pipe. I think I will repair the hole and just keep an eye on it. Can I get ideas on what to use to plug the hole? I know I can score an Ebay air box for $30... > > > ________________________________ > From: spike55_bmw > To: DSN_KLR650@yahoogroups.com > Sent: Sunday, September 25, 2011 4:57 PM > Subject: Re: [DSN_KLR650] Hole in my air box? > > > > I'd go with an exhaust leak too. The that's right above the transition point between exhaust header and muffler. > > Did the PO run an aftermarket muffler? Are you? It may not have been a good fit. I know that there was a recall (Pre '08 models) to tighten / replace any missing bolts (two) that holds the OEM muffler in place. A lose muffler may have allowed a leak. > > Do you see any filler material sealing the gap between the header and muffler? Even if you seal the airbox, a continuous stream of hot gases coming from a leak may cut it open again. > > I'd pull the muffler and make sure it has the ability to seal itself on that header. > > Don R100, A6F > > --- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > > > Yes, it is a hole. I stuck a piece of wire thru it and I could see the wire thru the filter side. My question now is, why did Kawasaki locate the exhaust so close to the plastic air box, and has anyone else ever had this problem before? Not knowing how long its been this way (I'm not the original owner), I'm wondering how much damage has been done with the unfiltered air that's been getting in. This bike has just under 13,000 miles. Maybe everybody should check their air boxes... > > > > > > > > [Non-text portions of this message have been removed] > > > > > > > [Non-text portions of this message have been removed] >

[David Nichols]

The hole is on the wrong side of the filter and allowed unfiltered air to get in. That's a good idea about a screw and washers, I'll look into it. I found another air box on Ebay with the same hole as mine: http://goo.gl/lvxrF I'm surprised I haven't heard about this problem before as I have read everything there is on KLR's ________________________________ From: spike55_bmw To: DSN_KLR650@yahoogroups.com Sent: Sunday, September 25, 2011 7:14 PM Subject: [DSN_KLR650] Re: Hole in my air box? The unsealed hole wouldn't be a problem as long as you don't get into deep water and the foam filter is still intact. I wouldn't get too hung-up on replacing the airbox. Use small bolt & nut / a fender washer on each side of the hole / silicone sandwiched in between. That would seal it for years and out of sight, out of mind. Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > The hole is forward of the exhaust joint but I can see how an exhaust leak could cause it. Because the muffler side slips over the header side the gases would be directed forward. The muffler is now off the bike, that's how I discovered this. I will make sure it seals when I put it back on. I'm planning on heat tile on the air box and insulating wrap around the pipe. I think I will repair the hole and just keep an eye on it. Can I get ideas on what to use to plug the hole? I know I can score an Ebay air box for $30... > > > ________________________________ > From: spike55_bmw > To: DSN_KLR650@yahoogroups.com > Sent: Sunday, September 25, 2011 4:57 PM > Subject: Re: [DSN_KLR650] Hole in my air box? > > > > I'd go with an exhaust leak too. The that's right above the transition point between exhaust header and muffler. > > Did the PO run an aftermarket muffler? Are you? It may not have been a good fit. I know that there was a recall (Pre '08 models) to tighten / replace any missing bolts (two) that holds the OEM muffler in place. A lose muffler may have allowed a leak. > > Do you see any filler material sealing the gap between the header and muffler? Even if you seal the airbox, a continuous stream of hot gases coming from a leak may cut it open again. > > I'd pull the muffler and make sure it has the ability to seal itself on that header. > > Don R100, A6F > > --- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > > > Yes, it is a hole. I stuck a piece of wire thru it and I could see the wire thru the filter side. My question now is, why did Kawasaki locate the exhaust so close to the plastic air box, and has anyone else ever had this problem before? Not knowing how long its been this way (I'm not the original owner), I'm wondering how much damage has been done with the unfiltered air that's been getting in. This bike has just under 13,000 miles. Maybe everybody should check their air boxes... > > > > > > > > [Non-text portions of this message have been removed] > > > > > > > [Non-text portions of this message have been removed] > [Non-text portions of this message have been removed]