backup reserve/ gps

[spike55_bmw]

I checked both of my '06 bikes (one has over 30,000 miles) and the airboxes are OK. Both are stock mufflers (best to sneak through private property at the end of a long trail). Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > 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] >

[David Nichols]

My exhaust was stock also. I'm sure it had a leak from what I have found. ________________________________ From: spike55_bmw To: DSN_KLR650@yahoogroups.com Sent: Sunday, September 25, 2011 7:55 PM Subject: [DSN_KLR650] Re: Hole in my air box? I checked both of my '06 bikes (one has over 30,000 miles) and the airboxes are OK. Both are stock mufflers (best to sneak through private property at the end of a long trail). Don R100, A6F

--- In DSN_KLR650@yahoogroups.com, David Nichols wrote: > > 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] > [Non-text portions of this message have been removed]

[Mike Frey]

And then, there s the (true!) story of my 2nd KLR: I bought it when it was only a year old, with less than 3000 miles on it. The original owner never took it off road (thankfully). After getting it, I was looking over the bike for loose bolts, etc and saw that he had drilled holes into the side cover of the air box the piece that you take off to get to the filter. Oh, an air box mod to increase flow , I thought while at the same time remembering that most people modify the snorkel or other area at the TOP of the air box. Let s see if he did anything with the filter itself . He had done something, all right when I opened it up, I saw that he had replaced the OEM filter with an aftermarket Uni. OK, but... As I gazed at the setup, I realized that the replacement filter was just an open sock (imagine cutting the leg portion of a tube sock and using that) rather than the closed-toe that it should have been. It was as good as having no filter at all! I immediately replaced it, and the bike seems no worse for wear, 4 years later. Mike From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of David Nichols Sent: Sunday, September 25, 2011 8:45 PM To: spike55_bmw; DSN_KLR650@yahoogroups.com Subject: Re: [DSN_KLR650] Re: Hole in my air box? 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]

[dooden]

I say patch hole with something heat resistant, and replace the seal/gasket tube thingy where the header ends and the pipe begins. If am seeing the photo correctly. Dooden A15 Green Ape

--- In DSN_KLR650@yahoogroups.com, "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/ >

[mark ward]

Comin g across North Dakota, my gas milege got crappy, (Lots of dusty dirt rds, = dirty air filter) Glad I had skins on, pulled it off stuck it in a ziplock and away ya go. Good thing We have that EXTRA reserve, Tilting an over loaded bike to get that extra gas, and GPS to show me 3 miles BACK instead of 32 ahead. 5.672 Gallons, YEE-HA [Non-text portions of this message have been removed]