airbox mod question

[Greg Autrey]

I have a 2006 KLR with 5200 miles. Been having a surging and dying problem. Removed both safety switches, took apart and cleaned petcock diaphram and carb, got to checking the valves and they are very tight. Both exhaust valves .05mm out of spec. Intake just below the low side spec. Kawasaki dealer supposedly checked them at 500 miles, I always thought an hour was not enough time to do it. Is this enough out of spec givin my miles to do any damage? Also, I am hoping that this solves my problem as I am off to Baja for ten days in April. Phoenix to Santa Rosalia, ferry across to Guyamas, back to Phoenix. Mostly dirt. Looking for a Baja Almanac if anybody wants to sell one. Thanks to all who have given me advice for this problem in the past. Greg in AZ 2006 KLR650, fully farkled.

[Blake Sobiloff]

On 3/22/07, Greg Autrey wrote:

> Is this enough out of spec givin my miles to do any damage?

Hi Greg! I'm not an engine expert, but I had similar concerns when I took ownership of my new-to-me KLR. The valves were at the bottom end of the range and then some. Advice from folks on the list said don't worry about it, and over 10,000 miles later my motor still seems to be running just fine. Now, I don't think that that gives us a free pass to ignore valve adjustments (tappy valves are happy valves!), but it seems that it isn't hugely detrimental if the valves get a bit tight, either. Have a great trip! -- Blake Sobiloff http://sobiloff.typepad.com/> http://sobiloff.typepad.com/klr_adventure/> San Jose, CA (USA)

[W.V. Doran]

Greg ... I have a Baja Almanac folding map you can borrow and I would not leave the country without adjusting the valves. Set them and forget them. If you need help adjusting them I can help, I have the tools and extra shims. WVDoran Scottsdale,AZ Greg Autrey wrote: I have a 2006 KLR with 5200 miles. Been having a surging and dying problem. Removed both safety switches, took apart and cleaned petcock diaphram and carb, got to checking the valves and they are very tight. Both exhaust valves .05mm out of spec. Intake just below the low side spec. Kawasaki dealer supposedly checked them at 500 miles, I always thought an hour was not enough time to do it. Is this enough out of spec givin my miles to do any damage? Also, I am hoping that this solves my problem as I am off to Baja for ten days in April. Phoenix to Santa Rosalia, ferry across to Guyamas, back to Phoenix. Mostly dirt. Looking for a Baja Almanac if anybody wants to sell one. Thanks to all who have given me advice for this problem in the past. Greg in AZ 2006 KLR650, fully farkled. WVDoran Scottsdale, AZ --------------------------------- Expecting? Get great news right away with email Auto-Check. Try the Yahoo! Mail Beta. [Non-text portions of this message have been removed]

[C L Cooper]

I opened up my air box recently. Removed the snorkel and L cutout... along with a number of other engine and exhaust mods. Link below was very helpful. http://www.angelfire.com/mo/motormark/mikescarbmod.html When I cut the airbox screen out there were wire stubs left sticking out of the air box moulding. I didn't like the thought that those could come loose and get into my new piston and cylinder. I cut them off as short as I could, worked them down to lie as flat as possible along the inside of the air box, and then dabbed JB Weld over all the wires. Came out very clean. Nice and smooth and no exposed wires. Patman's Dyno results really helped me make decisions about whether or not I wanted to and how much I wanted to spend on mods http://www.patmanracing.com/klrdyno.htm KLR FAQ is the info place. Regards, Chuck C San Diego, CA

On 4/3/07, corky69mobile wrote: > > Hello i am new to this group. And want to say hi to all klr's just got > mine last month just got the 500 mile service and now want a little > more power. got it piped and jetted stage 1. helped a little but > looking to do the airbox mod. but need a little help doing that anyone > know a good site that shows, explains it really well. > > > [Non-text portions of this message have been removed]