Need Help With Airbox - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 6 Old 01-10-2015, 07:50 AM Thread Starter
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Need Help With Airbox

I recently purchased my first KLR. It is a 2001 KLR 650 - but it needs some work (mainly the fork seals need replaced and the carb is gummed up). Here is a pic of my brand new bike.



Anyways, I purchased a new airbox off Ebay because the airbox that came with the bike was in terrible condition. I cleaned my new airbox yesterday, but I don't remember how all the various tubes are supposed to be connected. My question to you guys is this: Do I have the hoses connected correctly, or have I made a mistake? Thanks for the help! This is an excellent forum, where I've already learned a ton of information just in the past week alone.

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post #2 of 6 Old 01-10-2015, 11:02 AM
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Looks good to me. It will become obvious when you get it in there.

Welcome to the forum.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 6 Old 01-12-2015, 09:26 PM
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Quote:
Originally Posted by Rebel_2006 View Post
I recently purchased my first KLR. It is a 2001 KLR 650 - but it needs some work (mainly the fork seals need replaced and the carb is gummed up). Here is a pic of my brand new bike.



Anyways, I purchased a new airbox off Ebay because the airbox that came with the bike was in terrible condition. I cleaned my new airbox yesterday, but I don't remember how all the various tubes are supposed to be connected. My question to you guys is this: Do I have the hoses connected correctly, or have I made a mistake? Thanks for the help! This is an excellent forum, where I've already learned a ton of information just in the past week alone.

Rebel_2006,
I do see an Error.

The 'rubber flapper' valve, should be on the rearward fitting, the 'dirty side' of the air box.
The long hose, with a Cap Plug (Which I can NOT see, on the non-Standard Hose), should be attached to the forward nipple, the 'clean side' of the air box.
This keeps the dirt OUT, of the clean-side and Allows one to drain any 'crankcase' misting from the Clean-Side, as needed.

pdwestman
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Last edited by pdwestman; 01-12-2015 at 09:33 PM. Reason: added, (non-standard hose)
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post #4 of 6 Old 01-13-2015, 11:39 AM
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Regarding the long drain hose on the clean side of the air box: I find that the drain bottle or plug tends to become damaged or pulled off in the rough stuff which opens the air box to dirt. I've been cutting this hose up short and using a very effective plug in the hose for several years on bikes. To date no problems with oil filling the air box, and besides one does look around in there and wipe the interior with a white rag when doing filter service, right? The white rag shows up dirt very effectively, IME.
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post #5 of 6 Old 01-13-2015, 12:02 PM
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Normk,
How do you get a rag past the 'flame-arrester screen' into the Clean Side of the Air Box?

One can wipe out the dirty side with a rag, the side which the 'flapper valve' should be attached, but I usually just use the shop vac to get the chunks.
Then just wipe the sealing area.

pdwestman
Modify at "YOUR OWN RISK"!

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post #6 of 6 Old 01-13-2015, 12:09 PM
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I've removed the screen on several bikes including my present one. Otherwise I wipe the screen and area inside the filter looking for dirt. If any doubt, I pull the carb and wipe the carb inlet and airbox outlet. Dirt seems more evident on the air box side, perhaps because not as smooth?
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