help!!!

[muchgreed]

During my periodic 1500-mile air filter cleaning, this one being at 19500 miles, I observed a distinct burn mark on my air filter. Pulling the filter off its plastic frame, I noticed the frame was melted behind the burn mark. Further investigation resulted in the discovery of a hole punched through my air box near where the filter was burned. Much puzzlement ensued, as there was no debris in the airbox from the mysterious hole-puncher. Skipping ahead a few steps, it turns out that there was a crack in my muffler that must have been shooting a jet of very hot exhaust gas at my air box, melting the box, filter, and filter frame. For some pix, see http://home.comcast.net/~klr650_now/KLR3.html A Supertrapp muffler from Dual Star will soon be installed. Bryan B. 2004 KLR650 A18

[jokerloco9@aol.com]

How about taking a MIG welder and welding up the hole? Lot cheaper than a new muffler, that you are also going to have to do maintenance on. Jeff A20 [Non-text portions of this message have been removed]

[Ernie Campbell]

good luck in not pissing everyone off with that loud ass exaust Ernie Campbell

----- Original Message ----- From: muchgreed To: DSN_KLR650@yahoogroups.com Sent: Wednesday, July 12, 2006 9:00 PM Subject: [DSN_KLR650] Burned Air Filter During my periodic 1500-mile air filter cleaning, this one being at 19500 miles, I observed a distinct burn mark on my air filter. Pulling the filter off its plastic frame, I noticed the frame was melted behind the burn mark. Further investigation resulted in the discovery of a hole punched through my air box near where the filter was burned. Much puzzlement ensued, as there was no debris in the airbox from the mysterious hole-puncher. Skipping ahead a few steps, it turns out that there was a crack in my muffler that must have been shooting a jet of very hot exhaust gas at my air box, melting the box, filter, and filter frame. For some pix, see http://home.comcast.net/~klr650_now/KLR3.html A Supertrapp muffler from Dual Star will soon be installed. Bryan B. 2004 KLR650 A18 [Non-text portions of this message have been removed]

[wannabsmooth1]

--- In DSN_KLR650@yahoogroups.com, "muchgreed" wrote:

> > During my periodic 1500-mile air filter cleaning, this one being at > 19500 miles, I observed a distinct burn mark on my air filter. > Pulling the filter off its plastic frame, I noticed the frame was > melted behind the burn mark. > Further investigation resulted in the discovery of a hole punched > through my air box near where the filter was burned. Much puzzlement > ensued, as there was no debris in the airbox from the mysterious > hole-puncher. Skipping ahead a few steps, it turns out that there was > a crack in my muffler that must have been shooting a jet of very hot > exhaust gas at my air box, melting the box, filter, and filter frame. > Bryan B. > 2004 KLR650 A18 >

Saw this on a 2000 model with about 23K, too........ Something to watch for. all the best, Mike

[Ed Chait]

> good luck in not pissing everyone off with that loud ass exaust > Ernie Campbell

Actually, my ISD2 SuperTrapp with the regular core is not loud at all. I'm thinking of ordering the race core to see what that sounds like. Regards, ed A17

[Ernie Campbell]

How often do you have to repack it? Ernie Campbell

----- Original Message ----- From: "Ed Chait" To: "muchgreed" ; DSN_KLR650@yahoogroups.com>; "Ernie Campbell" Sent: Thursday, July 13, 2006 2:57 AM Subject: Re: [DSN_KLR650] Burned Air Filter > >> good luck in not pissing everyone off with that loud ass exaust >> Ernie Campbell > > > Actually, my ISD2 SuperTrapp with the regular core is not loud at all. > I'm thinking of ordering the race core to see what that sounds like. > > Regards, > > ed > A17 > >

[Ernie Campbell]

How often do you have to repack it? Ernie Campbell

----- Original Message ----- From: Ed Chait To: muchgreed ; DSN_KLR650@yahoogroups.com ; Ernie Campbell Sent: Thursday, July 13, 2006 2:57 AM Subject: Re: [DSN_KLR650] Burned Air Filter > good luck in not pissing everyone off with that loud ass exaust > Ernie Campbell Actually, my ISD2 SuperTrapp with the regular core is not loud at all. I'm thinking of ordering the race core to see what that sounds like. Regards, ed A17 [Non-text portions of this message have been removed]

[Mike Frey]

Before you take anything apart, start with the most simple check of all: Look at the shift lever and make sure it is not bent and rubbing against the engine case. That has happened to many experienced rider / mechanics who thought it was something broken and it was only the external shift lever sticking and binding against something. bigd88455 wrote:

> My A14 got stuck in 3rd gear. > I was told it was probably a clutch fork,either stuck or broke. > Can someone tell me where I can find some parts to fix this? > I know its gonna be a big job, but damn Im missin my bike. > It is my first bike, I bought it used with 23k miles on it, and have > been riding it for the last year rain or shine. > Gas prices are killin me. > >

[Ed Chait]

----- Original Message ----- From: "Ernie Campbell" To: "Ed Chait" ; "muchgreed" ; DSN_KLR650@yahoogroups.com> Sent: Thursday, July 13, 2006 6:44 AM Subject: Re: [DSN_KLR650] Burned Air Filter > How often do you have to repack it? > Ernie Campbell > ----- Original Message ----- > From: "Ed Chait" > To: "muchgreed" ; DSN_KLR650@yahoogroups.com>; > "Ernie Campbell" > Sent: Thursday, July 13, 2006 2:57 AM > Subject: Re: [DSN_KLR650] Burned Air Filter > > >> >>> good luck in not pissing everyone off with that loud ass exaust >>> Ernie Campbell >> >> >> Actually, my ISD2 SuperTrapp with the regular core is not loud at all. >> I'm thinking of ordering the race core to see what that sounds like. >> >> Regards, >> >> ed >> A17 I've only put about 500 miles on it so far, but it really hasn't gotten any louder than when it was brand new. I know that others have had to repack theirs with less miles than that, but so far I have not noted any change in decibel level. ed A17