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#Post#: 2933--------------------------------------------------
Brand New 2015 - Leaking dust through the air-filter
By: RiverRunner Date: June 23, 2015, 10:26 pm
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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.
#Post#: 2940--------------------------------------------------
Re: Brand New 2015 - Leaking dust through the air-filter
By: SDMF_Reaps Date: June 26, 2015, 11:53 am
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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.
#Post#: 3262--------------------------------------------------
Re: Brand New 2015 - Leaking dust through the air-filter
By: Adventure711 Date: November 14, 2015, 6:03 am
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You could look at the Rally Raid's $169.00 fix and poof, the
problem goes away.
#Post#: 3264--------------------------------------------------
Re: Brand New 2015 - Leaking dust through the air-filter
By: Rsquared Date: November 14, 2015, 8:40 am
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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...
#Post#: 3273--------------------------------------------------
Re: Brand New 2015 - Leaking dust through the air-filter
By: ChipStevens Date: November 15, 2015, 10:26 pm
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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.
#Post#: 3703--------------------------------------------------
Re: Brand New 2015 - Leaking dust through the air-filter
By: nbonds Date: August 10, 2016, 5:11 am
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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.
HTML https://youtu.be/BasxbJvtyBY
#Post#: 3704--------------------------------------------------
Re: Brand New 2015 - Leaking dust through the air-filter
By: RiverRunner Date: August 10, 2016, 12:19 pm
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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
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