Author Topic: Brand New 2015 - Leaking dust through the air-filter  (Read 535 times)

RiverRunner

  • Explorer
  • ***
  • Posts: 73
  • Karma: +0/-0
    • View Profile
Brand New 2015 - Leaking dust through the air-filter
« on: June 23, 2015, 10:26:03 pm »
I was really P.O.'ed when I took the paper filter out of my wife's brand new bike tonight, only to find a nice coating of dust in the airbox.........we have not yet been in dusty conditions.  My bike has a very fine coating as well.

This is really disheartening, I mean KTM has had faulty airboxes for how many years in this model?  OMG!

Anyone had this problem and found a fix?   I added a layer of grease around the filter where it fits to the airbox.  I've not had dust get by the filter in our last set of Huskies and Honda's.  Again, we haven't even been in dusty conditions yet.  Crap.

Social Buttons


SDMF_Reaps

  • Adventurer
  • ****
  • Posts: 105
  • Karma: +7/-0
  • North Eastern South Dakota
  • Location: North Eastern South Dakota
    • View Profile
    • Willow Creek Lake Weather
the molder left some extra material around the inside edge of the airbox opening.  If you trim it back with a razor blade it will usually fix your problem.

I think what happens is the filter gets pushed in by this extra material.  This pressure bulges the seating area of the filter just enough to let a little dust in.

Adventure711

  • Wanderer
  • *
  • Posts: 4
  • Karma: +0/-0
  • Location: Wentzville Mo.
    • View Profile
Re: Brand New 2015 - Leaking dust through the air-filter
« Reply #2 on: November 14, 2015, 06:03:38 am »
You could look at the Rally Raid's $169.00 fix and poof, the problem goes away.

Rsquared

  • Wanderer
  • *
  • Posts: 11
  • Karma: +1/-0
    • View Profile
Re: Brand New 2015 - Leaking dust through the air-filter
« Reply #3 on: November 14, 2015, 08:40:39 am »
I had the same thing happen on my 2014 690. I went with the Uni foam filter and grease around the base. Since then, I've been on numerous very dusty rides without any sign of leakage around the filter. It amazes me as well that KTM can't get this right. I've got the same issue on my 15 1190...

ChipStevens

  • Wanderer
  • *
  • Posts: 10
  • Karma: +1/-0
    • View Profile
Re: Brand New 2015 - Leaking dust through the air-filter
« Reply #4 on: November 15, 2015, 10:26:38 pm »
Hear is how I solved the air filter problem. My objective was simple make the air filter easy to service an a trip and use the stock air box. The problem with the stock foam filter is it is bulky, hard to clean, and requires grease to seal it up ( messy).  I purchase Uni Filter green bulk foam ( bf-1) it is 65 ppi and 5/8 in thick. The after market filters are a courser foam.  I then cut out a foam piece the same shape as the stock filter adding 3/4 in all the away around. Oiled up the foam placed it over the air box inlet and bolted the cover on. Since they are just a flat piece of foam they are easy to clean and oil and and don't take up a lot room. I have used this filter for several thousand miles all over Nevada, Arizona, and Moab area of Utah. In dusty areas I service or replace the filter every other day. The bottom of after market air filters sits on the floor of the air box so air can't get through because of this I think my filters surface area is about the same. Because of how compact the oiled foam is when the lid is on no grease is needed.

nbonds

  • Wanderer
  • *
  • Posts: 1
  • Karma: +0/-0
  • Location: Washington State
    • View Profile
Did a air-leak test on a new 690 to really find out what's going on with these dusty airboxes. We found an obvious leak on the flange of the airbox. Dust can get by it and go straight into the engine. Leaving this here for others in case it happens to anyone else. made a video so you can really see the problem.
https://youtu.be/BasxbJvtyBY

RiverRunner

  • Explorer
  • ***
  • Posts: 73
  • Karma: +0/-0
    • View Profile
Update to my original post:

I put the Rottweiler intake on both of our bikes a couple of months ago.  It was a pretty straightforward install.  The kit includes good instructions and there is a video on youtube.

We've done two weeks in the desert of northern Nevada since install.  I used two layers of filter skins on that trip and switched them out every two or three days, next trip I'd leave the bottom layer on for two of three changes of the top layer of cloth.  When I got home and cleaned the main Rottweiler filter, much less material came out of the filter than I expected and zero dust got through into the throttle body and silicone downtube.  I was VERY happy with the performance - plus I really like the sound when you go WOT!

I got the Rottweiler systems due to the leaking OEM airboxes and wanting to use (easily) filterskins.  We have the Safari tank on our bikes which really limits the access to the OEM filter.  If I didn't have the Safari, I'd also think about the UNI filter - prefilter setup from UNI Australia - really nice folks.(google it).  This setup gets you a new lid to the OEM airbox with a foam prefilter that is designed to have a filterskin over the top.  The UNI is cheaper than the Rottweiler, but the Rottweiler leaves you a place for a glovebox under the seat!

RR