holes in air filter cover - Kawasaki KLR 650 Forum
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post #1 of 28 Old 12-20-2009, 02:22 AM Thread Starter
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holes in air filter cover

I recently bought a 2002 KLR 650, and was told that it has a K&N filter. By golly, it does, but somebody (The DPO)drilled two 10 mm holes in the the cover.
How do I insert a picture here?

Now, is this something folks do when installing a K&N filter? Or was the DPO paranoid that the stock air box would not allow enough flow?

Also, I've seen some add on seat padding on photos here. Can anyone tell me about those, and where to find them?

Thanks ahead of time. This is the first KLR forum I've joined, or even looked at for that matter.

SK
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post #2 of 28 Old 12-20-2009, 06:19 AM
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Removing the airbox cover or punching holes in it is a standard modification, it's even addressed in the instructions of a re-jetting kit.

You can find the ATV seat cover at Walmart.com for $18.00

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post #3 of 28 Old 12-20-2009, 09:24 AM
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Quote:
Originally Posted by cwo4sailor View Post

You can find the ATV seat cover at Walmart.com for $18.00

http://www.walmart.com/catalog/produ...ct_id=10727537
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post #4 of 28 Old 12-20-2009, 09:27 AM
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I swiss-cheesed my airbox too. Woulda been easier to just take the whole door and snorkel off. LOL

Seats? I wanna swap out with my bro-in-laws '07 if there's a perfect fit. He says it's too gushy, mine's a hemmorhoid crusher. We'd both be happy.

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post #5 of 28 Old 12-20-2009, 01:11 PM
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Hey man,

Welcome to the group! This is the best bunch of people I have found on the forums however some of the others provide some great tech posts so don't count them out. I just mean to say that we here have a very civilized group and there are some members who really know their stuff present also.

Stick around,

Ard

Spinning / flashing LED tail light;Dished seat;Nerf Bars;Panniers and rack;Aluminum skid pan;Master cylinder guard;tall shield;Heated gel grips;Acerbis Rally Pro guards with spoilers;Superbike low front fender;Doo upgrade;16T counter sprocket; K&N filter and box mod;GPS mount;Dash with voltage meter & clock;1" raising links;T bypass mod;anti vibe bars;anti vibe mirror mounts;Euro light switch; Aluminum choke leaver;new dry cell Super battery;Mefo Expolere's;New bearings and races
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post #6 of 28 Old 12-20-2009, 01:12 PM
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I'm not positive about where the holes were drilled based on your post. Reason I ask is, most folks who do the airbox mod I'm familiar with do bigger holes and more of them????

You can set up an account at photobucket and then post pics here. Since the holes are small, throw a little square of tape over them and take a ride and see if you can tell a difference.

But yeah, pretty standard operating procedure if the holes are what I think they are (10 mm seems a little small...mine has five holes drilled in it and they are near 3/4ths of an inch) . A pic would help.




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post #7 of 28 Old 12-20-2009, 01:35 PM Thread Starter
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More questions...

Quote:
Originally Posted by cwo4sailor View Post
Removing the airbox cover or punching holes in it is a standard modification, it's even addressed in the instructions of a re-jetting kit.

You can find the ATV seat cover at Walmart.com for $18.00
...No doubt leading to more.

Is there any liturature on perforating the air box? or is this an empirically inspired practice? Frankly I'd be concerned about water getting in, although I've yet to go to those extremes with my new ride. Hey, it's been 35 years since the last motorcycle. Judging from the photos on this forum, it looks to be inevitable. I recall having water coming through the doors of my old Land Cruiser, so I do have the inclination.

I'll look into photobucket.
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post #8 of 28 Old 12-20-2009, 02:09 PM
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Quote:
Originally Posted by sarthurk View Post

I'll look into photobucket.
You can upload and store photos right here, http://www.klrforum.com/vbimghost.php?do=upload it's the VB Image Host button at the top of the page. Once uploaded and hosted find your photo under My Images then copy and paste the "BB Code IMG" into your post.

Gray-haired riders donít get that way from pure luck.

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post #9 of 28 Old 12-20-2009, 02:10 PM
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If you get into water that deep you will probably experience other difficulties than water getting through those two 10mm holes. I forget what I did to mine but I believe I took the snorkel off the box. It looked to be the easiest way to promote better air flow. It's been a couple years and I have not looked prior to posting.

The deepest water I ever crossed with my motorcycle threatened to stall me out due to excessive steam and associated moisture long before reaching the air box. I made it through and crossed on the return trip the next day also. The best advice I can offer is this, remember that you are riding a two wheeled machine not a 700cc King Quad. Unless You can see the bottom the biggest scare is hitting submerged rocks or logs. This is a real danger here in AK. when you take a track into the bush.

I quickly learned that if I wanted to keep the bike in good condition there were just some things that the bike is too big for and I too old. If I gotta cross water deep enough to drown my bike I wear waders, take a fly rod and walk.

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post #10 of 28 Old 12-20-2009, 11:08 PM
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If you are planning on riding in any dusty areas you may want to get rid of the K & N and replace with the stock or a Uni filter. Mine has left me cleaning the filter on the side of the trail more than once.

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