2018 KLR650 Blown Top End (1300 miles)
Hello gang. Has anyone ever seen this problem? I just recently installed the Eagle Mike kit in the subject bike for a friend and did the typical mods to open the airbox top. It already had a free flow DG exhaust on it. The last thing I did was remove, clean and re-oil the air filter.
When I went to reinstall the air filter and was wiping clean the inside of the airbox I noticed the wire mesh permanently mounted between the carb and the filter. Huh? I have never seen this on a motorcycle and it looked nasty so I called a KLR guru and asked what the heck it was for. He said he wasn't sure but it was probably to prevent some random small rock or anything else from getting the the carb. I found that strange since that is what the filter itself does but on a super fine level. He said all KLR's have that screen, they always look sort of nasty but it's not really hurting anything. So, I buttoned up the machine, took it for a test ride and that Eagle Mike kit was impressive. Everything worked GREAT!!
Fast forward no more than 50 miles later and a new owner reports white smoke billowing out of the exhaust. The Kawasaki shop found that that wire mess mentioned above actually rusted, broke into pieces and got sucked into the cylinder. It was obviously made out of some sort of corrosive material instead of stainless or brass. The photo I have seen shows that the screen is brittle and breaking apart in pieces. The quote to repair it is $1,600.00. This bike is hardly even broken in with only 1300 miles. I am shocked that Kawasaki would install anything in the path of the air intake that could rust or come loose. Super disappointed.
Last edited by Rick Hall; 05-13-2020 at 08:34 PM.