DragBikeMike
Serious Thumper
Offline
SuzukiSavage.com Rocks!
Posts: 4166
Honolulu
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JOG, I love the "Religious Ritual" comment. I agree that washing and re-oiling filters is pretty much a pain. I'm always searching for that last little pit of go-power so I guess you could say I'm the religious type. The stock filter sure is easy to R&R.
Eau de sauvage, while I was doing additional tests on the airbox over the weekend, I had the opportunity to peer down the throat of the airbox (with the snorkel removed) at the fitup on the left side of the filter. I noted there is a hook fit along that left side, and the square edge of the filter element has to slip under that hook. When I misaligned the K&N with the hook, such that the edge of the filter butted against the edge of the hook rather than slip under it, the filter fit exactly like the photos you attached to your post. It is significantly more difficult to slip the K&N into place than it is to slip the stock filter into place. The stock filter has a taper on the left edge that, looks to me, like its intended to allow the user to install the element at an angle, slip the edge under the hook fit, and then pivot the filter forward and into place. The K&N doesn't incorporate the tapered edge, which makes it more difficult to slip under the hook.
Regardless of the reason for your fitup problem, if you weren't satisfied with that filter, K&N should have taken care of you. Did they refund your money, send you another element, do anything to make you happy, or just blow you off?
I don't understand your question regarding "correct filter foam with correct oil". I tested the stock filter (pleated fabric/paper, no oil specified), the K&N (pleated gauze with K&N specified oil), and a homebrew assembly (stock frame with a polyester filler material oiled with canola oil). For the homebrew assembly, I made a wood frame to simulate the stock steel frame. I didn't test any sort of foam filter.
If you are interested in improved performance, and don't want to mess around with cleaning and oiling filters, you can realize significant improvements in flow with some simple (and free) modifications to your airbox. There's a lot more flow available with the stock element. Take a look at the latest entries to my post "Airbox Performance Tests", posted yesterday.
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