2018 KLR650 Blown Top End (1300 miles) - Page 2 - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #11 of 34 Old 05-15-2020, 08:53 AM
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Originally Posted by JoeExotic View Post
Maybe it was caused by fuel containing ethanol?



Ethanol is corrosive.


Even at 10% Ethanol Gas, which can be up to 10%, thatís 3.06 teaspoons per gallon.

If he ran E-85 in the bike I could see it, but normal Gas thatís 10% or less, hard to see.

But you are correct, if he did run E-85 it would eat that metal up!


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post #12 of 34 Old 05-15-2020, 09:02 AM Thread Starter
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Just plain old 87 Octane pump gas its entire life. Nothing weird or special.
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post #13 of 34 Old 05-15-2020, 10:22 AM
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Yep, the mystery deepens.......no, 10% ethanol wouldn't do it as there are tens of thousands of KLR's running around using that fuel without issue.

1st filter change and bike never used in any environment that explains the issue? wow........obviously the screen was exposed to some extremely corrosive element at some point whether it was before, during or after assembly.....I'm guessing that you didn't notice any other corrosion anywhere on the bike?

Don't kick yourself too much; hindsight is 20/20 and it would be pretty hard to predict this on a bike that was less than 6 months old.

I'd love to figure this one out but I'm starting to think it will be one of those "unsolved mysteries". :-(



Dave
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post #14 of 34 Old 05-15-2020, 10:30 AM
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Vision 1: I see a forklift driver unloading a boat in Thailand and dropping a crate of KLR airboxes in the ocean......crate retrieved, airboxes dried out and installed in new KLR's to be sold to unwitting owners.....

Vision 2; I see a KLR idling in a garage beside a forklift battery being charged and ingesting some of the acidic offgassing.....

Vision 3; Dude builds furniture in his shop (where he keeps his KLR stored) and the air has propellants from the glue he uses suspended in it.....KLR is left idling to warm up in this environment several times....

That's all I got. I will say that Vision 3 was a reality with a heat exchanger in my shop; our insulation glue offgassing ate right through it in a short time.


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post #15 of 34 Old 05-15-2020, 11:03 AM
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Originally Posted by AFMoulton View Post
Even at 10% Ethanol Gas, which can be up to 10%, that’s 3.06 teaspoons per gallon.

If he ran E-85 in the bike I could see it, but normal Gas that’s 10% or less, hard to see.

But you are correct, if he did run E-85 it would eat that metal up!


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I think you have your teaspoons & tablespoons mixed up. Isn't there 3 teaspoons per 1 tablespoon and 2 tablespoons per ounce?
But 12.8 ounces = 10% of one gallon.

I think that E-85 fuel would only be corrosive to carb parts and everything forward & internal of the engine. There should not be any reversion of fuel from back out of the carburetor to get E-85 onto that flame arrester screen.

Rick Hall,
The only thing that I can think of that might corrode the screen like that might be Sulfuric Acid fumes from an overcharging battery, with a miss routed battery vent hose (that would be really weird). That could potentially be a dealer preparation error. Someone should check the battery fluid level & vent hose routing.

And your 2 stroke dirt bikes doesn't use nor need an air filter flame arrester, the reed valves prevent any possible flash back.

I have a heat melted 2015 air box in my shop. I think I'll go rub some battery acid on its screen.

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post #16 of 34 Old 05-15-2020, 11:29 AM
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Originally Posted by pdwestman View Post
The only thing that I can think of that might corrode the screen like that might be Sulfuric Acid fumes from an overcharging battery, with a miss routed battery vent hose (that would be really weird). That could potentially be a dealer preparation error. Someone should check the battery fluid level & vent hose routing.
That's an excellent observation, particularly if the bike was hooked to a battery charger.....maybe one that isn't a "smart" maintenance charger that shuts down when the battery reaches full charge. I was sorta headed in that direction with my "tongue in cheek" post above but it would take something that corrosive IMO


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post #17 of 34 Old 05-15-2020, 11:55 AM
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Quote:
Originally Posted by pdwestman View Post
I think you have your teaspoons & tablespoons mixed up. Isn't there 3 teaspoons per 1 tablespoon and 2 tablespoons per ounce?
But 12.8 ounces = 10% of one gallon.
Indeed, 10% ethanol in a gallon of pump gas is 76.8 teaspoons, and not 3.06 teaspoons as reported previously.

Regardless of the concentration, ethanol did not damage that spark arrestor screen.

There's something fishy going on here.

Jason
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post #18 of 34 Old 05-15-2020, 12:08 PM
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Originally Posted by pdwestman View Post
I think you have your teaspoons & tablespoons mixed up. Isn't there 3 teaspoons per 1 tablespoon and 2 tablespoons per ounce?
But 12.8 ounces = 10% of one gallon.

Yep! You are 100% right, my fault, I was looking at the amount of water suspended in E-10 Gas. . Thank you for the correction.

Here was what I was looking at.

I do think the Dropping crates into the ocean thing could be a cause. Where is this bike located also?



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post #19 of 34 Old 05-16-2020, 06:44 AM Thread Starter
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Just 87 Octane fuel and the bike has been in a nice garage from day one. There is absolutely nothing else on this bike that doesn't look brand new including all the surfaces of all parts, aluminum and steel. All hardware looks brand new. Nothing on this bike shows any signs of any corrosion. It has scratches on the plastics from the one off road journey we took it on. Bazaar situation.
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post #20 of 34 Old 05-16-2020, 06:46 AM
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Just 87 Octane fuel and the bike has been in a nice garage from day one. There is absolutely nothing else on this bike that doesn't look brand new including all the surfaces of all parts, aluminum and steel. All hardware looks brand new. Nothing on this bike shows any signs of any corrosion. It has scratches on the plastics from the one off road journey we took it on. Bazaar situation.


Could he of cleaned it with something?


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