[trq427]

Bought a 2010 KLR last fall, original owner, 70 yo,1100 original miles. Today, did a Thermo Bob, oil/filter change, clean lube chain, progressive front springs and dumped the fuel tank, refueled with fresh premium non ethanol fuel.I put a couple of gallons of fuel in it last year, only rode about 130 miles before putting it away for the season, but was really unaware of the condition of the existing fuel, I'm now thinking it may had been stale,, maybe real stale. Obviously, bike was ridden very little during those years. As it warmed up in the cold air, I noticed the front pipe glowing red, obviously a bad mixture. I throttled it between 1K and 3K for a few minutes, As it warmed up, I'm suspecting the fresh fuel may have taken hold, along with the thermo bob, and things quickly cleaned up, engine running great and great throttle response. I did not ride it, too cold, plus haven't reinstalled the plastic yet.
As I changed to a new UNI filter, I noticed the very bottom and rear of the air box had a hole melted in it, obvious from the exhaust heat. I haven't looked real close, but the clean side of the box seems good, I'm wondering if there could be a leak in the joint, plan on investigating further tomorrow morning. New to the KLR, hoping for opinions on these conditions.

 

[garrettL]

If its the "dirty side" of the air box, not a huge deal but I would find a way to seal it if you can. If there are any holes in the front-bottom of the air box that will cause particulate to go straight into your engine.

The joint is under the front and after reading on here it seems to be a once in a while problem, definately worth correcting

 

[Johntheskier]

Check the nut/bolt on the exhaust clamp. They tend to work loose and melt a hole in the bottom of the airbox. Ask me how I know.

 

[MVMike]

Did you have your Enricher On by chance? If not your Enricher may be stuck open letting the engine run rich. That will glow the pipe red hot very quickly. Check that the plastic nut is full threaded into the carb so the needle is fully seated when the Enricher is Off. These often get broken or cross threaded and stripped. Easy to replace. Many accidental melting events over the years reported here leaving the Enricher on during warmup. Should not be used for high idle warmup. Besides the air box hole you found it can melt the plastic pipe nipple off the bottom of the coolant recovery tank and can melt the leading edge of the rear fender in front of the rear tire near the air box.

 

[trq427]

Did you have your Enricher On by chance? If not your Enricher may be stuck open letting the engine run rich. That will glow the pipe red hot very quickly. Check that the plastic nut is full threaded into the carb so the needle is fully seated when the Enricher is Off. These often get broken or cross threaded and stripped. Easy to replace. Many accidental melting events over the years reported here leaving the Enricher on during warmup. Should not be used for high idle warmup. Besides the air box hole you found it can melt the plastic pipe nipple off the bottom of the coolant recovery tank and can melt the leading edge of the rear fender in front of the rear tire near the air box.

I'm thinking you hit the nail on the head! I have warmed it up a few times with the "choke"(I now stand corrected and should have known better),, using it for high idle purpose, and never really thought about the function of the "enricher". Yeah, I can see the engine being way fat causing a rich situation and overheating the exhaust. Thanks for the response, and the education.

 

[pdwestman]

The exhaust AirInjectionSystem (AIS) used on the 2008+ bikes, combined with over-use of the cold start enrichener circuit (one to two minutes is normally enough) causes the un-burnt gases from the combustion chamber to finish burning in the exhaust port & header pipe.
Which causes the header pipe to 'glow' when the vehicle is motionless, no cooling air flowing over it, to cool it.
Many owners 'Delete' that 'cleaner air' spaghetti and install a block-off cap into its air port. next to the spark plug.

https://www.eaglemike.com/Air-injection-blockoff-kit-AIS.htm?categoryId=-1

This also reduces trailing throttle after-fire/popping from the muffler, during normal riding.

 

[trq427]

The exhaust AirInjectionSystem (AIS) used on the 2008+ bikes, combined with over-use of the cold start enrichener circuit (one to two minutes is normally enough) causes the un-burnt gases from the combustion chamber to finish burning in the exhaust port & header pipe.
Which causes the header pipe to 'glow' when the vehicle is motionless, no cooling air flowing over it, to cool it.
Many owners 'Delete' that 'cleaner air' spaghetti and install a block-off cap into its air port. next to the spark plug.

https://www.eaglemike.com/Air-injection-blockoff-kit-AIS.htm?categoryId=-1

This also reduces trailing throttle after-fire/popping from the muffler, during normal riding.

Yup,,as a GM Tech at a Chevy dealership in the 70's, I lived the years of GM A.I.R. pumps, starting late 66, more prevalent in 67 thru 69. Then came dogged down cams, finally converters, dark days for performance. AIR pump injected fresh air in the exhaust manifolds to re ignite unburned gases, an early attempt to clean up idle,, especially in stop and go states and cities like southern California. Makes perfect sense.

 

[trq427]

LOL,, like how Eagle Mike doesn't endorse eliminating federal air cleaning systems,,"to block off while running mixture tests",,,LOL In my day, we NEVER pulled a catalytic converter,,we installed "test tubes" for driveabilty issue diagnostic.

 

[MN Willie]

LOL,, like how Eagle Mike doesn't endorse eliminating federal air cleaning systems,,"to block off while running mixture tests",,,LOL In my day, we NEVER pulled a catalytic converter,,we installed "test tubes" for driveabilty issue diagnostic.

I'm going to be performing some "Testing" soon!

Willie

 

[PeteK]

Do the Gen3's also have that AIS injection port in the top of the head? Or is that handled by the FI system now?

 

[KLR-Mule]

Do the Gen3's also have that AIS injection port in the top of the head? Or is that handled by the FI system now?

Yes

 

[SirMarksAllot]

Learned this when I was idling to check for leaks after the T-Bob install.

I now have a heat shield between the header and the coolant reservoir nipple. It prevents NMS. (Nipple Melting Syndrome)!

 

[KLR-Mule]

View attachment 40933
Learned this when I was idling to check for leaks after the T-Bob install.

I now have a heat shield between the header and the coolant reservoir nipple. It prevents NMS. (Nipple Melting Syndrome)!

Is your AIS deleted?

 

[SirMarksAllot]

Is your AIS deleted?

It wasn’t at the time, that was about 9 months ago. Deleted it and emissions in the last few weeks.

 

[KLR-Mule]

It wasn’t at the time, that was about 9 months ago. Deleted it and emissions in the last few weeks.

Check it now and see if it still glows. I’m thinking it won’t now…

 

[SirMarksAllot]

Check it now and see if it still glows. I’m thinking it won’t now…

@KLR-Mule Where did you get the truck horn on your bike? Did you use the stock wiring and just modify the connections?

 

[Thumper1]

Is your AIS deleted?

I am just gunna knock this out as it’s not what I’m used to in any bike I have had (all older models ) and don’t like it. Hopefully helps a bit.

Thermo bob on , and A few other mods including 2 heat shields where they need to be…

New pipe shopping as well ..

And I ride the hell out of this thing and love it..!

2014 — All Good 👍

 

[KLR-Mule]

@KLR-Mule Where did you get the truck horn on your bike? Did you use the stock wiring and just modify the connections?

I bought the biggest & loudest horn at Autozone for about $30. I believe it’s a dorman 132dB high-tone.
On my gen 3, I removed the charcoal canister garbage & stuck it in its place. Used the existing wiring. It took all of 5mins to install.

I did the same exact thing with my previous 2018 KLR, and mounted it somewhere near the upper portion of the coolant reservoir IIRC.