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Brand New 2015 - Leaking dust through the air-filter

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RiverRunner:
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.

SDMF_Reaps:
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:
You could look at the Rally Raid's $169.00 fix and poof, the problem goes away.

Rsquared:
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:
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.

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