2018 KLR650 Blown Top End (1300 miles) - Page 3 - 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 #21 of 34 Old 05-20-2020, 06:54 PM
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Near the ocean?

I once ran into a corrosion problem with a customer only 1km from a salt water seaport. The warehouse area was indoors but they tended to leave doors open due to the tropical heat. Please note this customer issue had nothing to do with motorcycles.

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post #22 of 34 Old 05-20-2020, 07:47 PM
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I've spent the last week dribbling fresh sulphuric battery acid on the screen of the heat melted air box every morning & then plugging in the 10 amp battery charger onto a POS battery to fumigate the screen all day.

The screen is dis-colored kinda' white or gray depending on area, not silver like it was. But not a hint of rusty brown.
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post #23 of 34 Old 05-20-2020, 08:05 PM
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The implicit assumption is that all screen mesh is the same material. Could be a subpar or cheaper material was used instead of the standard one.

I have seen this a number of times where a supplier will send the "golden sample" to meet the technical requirements and ongoing shipments only meet the price point.
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post #24 of 34 Old 05-21-2020, 09:55 AM
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...I think I'd be having a "chat" with the dealer and Kawasaki on this - there seems to be no logical reason and given the age, low mileage and the fact that this was the first air filter service all points to a pre-existing problem.

Dave
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post #25 of 34 Old 05-21-2020, 06:31 PM
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Quote:
Originally Posted by DPelletier View Post
...I think I'd be having a "chat" with the dealer and Kawasaki on this - there seems to be no logical reason and given the age, low mileage and the fact that this was the first air filter service all points to a pre-existing problem.

Dave
I agree with Dave; there's something fishy going on here.

Jason
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post #26 of 34 Old 05-22-2020, 03:17 AM
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Rick Hall You mentioned an after market exhaust system.

One of the knowledgeable members has often warned that a loose clamp can allow hot exhaust gas to melt a hole in the clean air side of the air box. Is it possible that exhaust gas has leaked into that air box and caused the problem? I notice in the photo that there is a lot of crap sitting around in an area that should be clean.

Or is it possible that a previous owner has replaced the air box with an old weathered air box after noticing that exhaust gas has melted a hole in the original air box? I know the bike has not done many miles, but some bikes get sold at pretty low mileage

Last edited by timberfoot; 05-22-2020 at 03:20 AM.
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post #27 of 34 Old 05-22-2020, 01:02 PM
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@Rick Hall - Just curious. Since you were the last person to work on the bike is the owner trying to blame you? Situations like this is why I hesitate to work on anyone else’s bike.

.

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

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post #28 of 34 Old 05-23-2020, 10:41 AM
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this is one odd duck of a failure mode. I tend to think it got run without the foam filter for some time. still how the screen corroded / dissolved is crazy, But the battery which could be ham fisted / spilled is only 6 inches away give or take. Still not sure how a spilled battery gets liquid into the box. uh if someone could run a quick test?? jus kiddin

A overcharged battery outgassing is another potential causal area. but still . . . just about have to think what we observe of that screen had to be chemical in nature. Chipmonks would have to chew their way through to foam to get at the delicious metal screen. I have heard of mice chewing on wiring so . . . .

***no chipmonks were harmed in the typing of this message. ****

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post #29 of 34 Old 05-23-2020, 10:56 AM
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looking at the pdf pic again, the mesh screen looks like it is clogged with saw dust or similar, again pointing to the foam filter not being there or mis installed.

How so much particulate got in there may be part of the mystery. Then how so much of it is missing?? what chemicals did it see?

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post #30 of 34 Old 05-23-2020, 11:10 AM
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Quote:
Originally Posted by line6distortion View Post
looking at the pdf pic again, the mesh screen looks like it is clogged with saw dust or similar, again pointing to the foam filter not being there or mis installed.
I agree. What I would like to know is what exactly the rider was doing at the time of the failure. How fast, on the throttle etc?? Did the bike slow down and speed up again before the failure?

Looks like the screen is totally plugged. Is it possible, that at speed enough suction on the intake stroke could have pulled the screen into the engine? That's my long distance diagnosis. We're not getting the whole story here. I think this is more an owner issue than a Kawasaki issue. Expensive mistake.

.
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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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