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Old 07-16-2014, 09:17 AM   #766
like2lean
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Quote:
Originally Posted by wilmar13 View Post
If it isn't clear from the pics, I can tell you will absolute certainty, no ambiguity about it .
No doubt about that, I meant whether the engine issue was caused by dirt injestion or some other failure. Certainly possible, but I've seen MUCH dirtier boxes on all kinds of engines with far more miles not suffer the kind of problems yours is having. At least you'll get hassel free service since you don't have the dreded Uni installed that the dealers are all so hard for!
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Old 07-16-2014, 12:29 PM   #767
hewhohesit8s
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When installing the Uni ...

So I installed the Uni on my 2014 R yesterday... I managed to turn a 90 min job into 6 hours. So I thought I would pass on a few installation tips.

1 - Make sure you disconnect the Quick Disconnect hose before you attempt to pull out the tank. It makes pulling out the tank easier.

2 - When it falls into the bike body, you can retrieve the rubber bushing that is part of the main tank retention bolt using a long allen key held by pliers. Be patient. Swearing does not actually make the retrieval faster.

3 - Before you screw the top half of the air box back on after installing the Uni, make sure you remove the flashlight you were using to examine the airbox from the airbox. Otherwise, you will need to remove the top half of the airbox to retrieve the flashlight.

4 - the small pannel-like flap on the rear of the airbox is just attached to a hole on the top of the airbox. It is not big enough to retrieve any flashlights that might have been left in the airbox.

5 - it is best to re- install the side rubber bushings on the tank holding screws AFTER you have reinstalled the tank. Installing the bushings before installing the tank will lead to the bushings getting crushed and require pulling off the tank.

6 - A half full tank of gas is enough to crush your fingers if you hold the tank the wrong way when reinserting rubber bushing that is part of the main tank bolt.

7 -If, despite having been told not to, you do remove the airbox flap, remember to re-screw in the top two screws at the top of the airbox. Otherwise you will need to remove the tank again, after you thought you were all done, to reapply the screws once you notice them among the tools as you gather them to put them away.

Installing the Uni confirms that I am correct in letting the dealer perform all maintenance on my bikes.
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Old 07-16-2014, 12:39 PM   #768
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Lol! Good one. I feel your pain. It's abitch to get to the air box :)
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Old 07-16-2014, 12:46 PM   #769
scudrunner82
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Quote:
Originally Posted by hewhohesit8s View Post
So I installed the Uni on my 2014 R yesterday... I managed to turn a 90 min job into 6 hours. So I thought I would pass on a few installation tips.

1 - Make sure you disconnect the Quick Disconnect hose before you attempt to pull out the tank. It makes pulling out the tank easier.

2 - When it falls into the bike body, you can retrieve the rubber bushing that is part of the main tank retention bolt using a long allen key held by pliers. Be patient. Swearing does not actually make the retrieval faster.

3 - Before you screw the top half of the air box back on after installing the Uni, make sure you remove the flashlight you were using to examine the airbox from the airbox. Otherwise, you will need to remove the top half of the airbox to retrieve the flashlight.

4 - the small pannel-like flap on the rear of the airbox is just attached to a hole on the top of the airbox. It is not big enough to retrieve any flashlights that might have been left in the airbox.

5 - it is best to re- install the side rubber bushings on the tank holding screws AFTER you have reinstalled the tank. Installing the bushings before installing the tank will lead to the bushings getting crushed and require pulling off the tank.

6 - A half full tank of gas is enough to crush your fingers if you hold the tank the wrong way when reinserting rubber bushing that is part of the main tank bolt.

7 -If, despite having been told not to, you do remove the airbox flap, remember to re-screw in the top two screws at the top of the airbox. Otherwise you will need to remove the tank again, after you thought you were all done, to reapply the screws once you notice them among the tools as you gather them to put them away.

Installing the Uni confirms that I am correct in letting the dealer perform all maintenance on my bikes.

Funniest post I've read in a long while.
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Old 07-16-2014, 01:06 PM   #770
DiasDePlaya
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Quote:
Originally Posted by hewhohesit8s View Post
So I installed the Uni on my 2014 R yesterday... I managed to turn a 90 min job into 6 hours. So I thought I would pass on a few installation tips.

1 - Make sure you disconnect the Quick Disconnect hose before you attempt to pull out the tank. It makes pulling out the tank easier.

2 - When it falls into the bike body, you can retrieve the rubber bushing that is part of the main tank retention bolt using a long allen key held by pliers. Be patient. Swearing does not actually make the retrieval faster.

3 - Before you screw the top half of the air box back on after installing the Uni, make sure you remove the flashlight you were using to examine the airbox from the airbox. Otherwise, you will need to remove the top half of the airbox to retrieve the flashlight.

4 - the small pannel-like flap on the rear of the airbox is just attached to a hole on the top of the airbox. It is not big enough to retrieve any flashlights that might have been left in the airbox.

5 - it is best to re- install the side rubber bushings on the tank holding screws AFTER you have reinstalled the tank. Installing the bushings before installing the tank will lead to the bushings getting crushed and require pulling off the tank.

6 - A half full tank of gas is enough to crush your fingers if you hold the tank the wrong way when reinserting rubber bushing that is part of the main tank bolt.

7 -If, despite having been told not to, you do remove the airbox flap, remember to re-screw in the top two screws at the top of the airbox. Otherwise you will need to remove the tank again, after you thought you were all done, to reapply the screws once you notice them among the tools as you gather them to put them away.

Installing the Uni confirms that I am correct in letting the dealer perform all maintenance on my bikes.
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Old 07-16-2014, 02:15 PM   #771
kag
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Old 07-16-2014, 04:17 PM   #772
TDsurf
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And I thought I was the only one..

The bright side is that you can now do the air box service better than the dealer. Love your post.


Quote:
Originally Posted by hewhohesit8s View Post
So I installed the Uni on my 2014 R yesterday... I managed to turn a 90 min job into 6 hours. So I thought I would pass on a few installation tips.

1 - Make sure you disconnect the Quick Disconnect hose before you attempt to pull out the tank. It makes pulling out the tank easier.

2 - When it falls into the bike body, you can retrieve the rubber bushing that is part of the main tank retention bolt using a long allen key held by pliers. Be patient. Swearing does not actually make the retrieval faster.

3 - Before you screw the top half of the air box back on after installing the Uni, make sure you remove the flashlight you were using to examine the airbox from the airbox. Otherwise, you will need to remove the top half of the airbox to retrieve the flashlight.

4 - the small pannel-like flap on the rear of the airbox is just attached to a hole on the top of the airbox. It is not big enough to retrieve any flashlights that might have been left in the airbox.

5 - it is best to re- install the side rubber bushings on the tank holding screws AFTER you have reinstalled the tank. Installing the bushings before installing the tank will lead to the bushings getting crushed and require pulling off the tank.

6 - A half full tank of gas is enough to crush your fingers if you hold the tank the wrong way when reinserting rubber bushing that is part of the main tank bolt.

7 -If, despite having been told not to, you do remove the airbox flap, remember to re-screw in the top two screws at the top of the airbox. Otherwise you will need to remove the tank again, after you thought you were all done, to reapply the screws once you notice them among the tools as you gather them to put them away.

Installing the Uni confirms that I am correct in letting the dealer perform all maintenance on my bikes.
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Old 07-16-2014, 07:06 PM   #773
PineyMountainRacing
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The second time was much easier, and quicker.
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Old 07-16-2014, 08:51 PM   #774
wr2nxt
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Air box

Ditto.... what he said.
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Old 07-16-2014, 10:35 PM   #775
CaliBerger
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Was thinking about the airbox problem today and wondering exactly how prevalent it is
In my industry, product registries are created that allow for easy statistical analysis and rapid contact of affected individuals when problems are detected
Relatively new here so not sure how best to accomplish this but seems as if a registry of sorts could be created by polling 1190 owners who have had the courage to look inside their airbox and ‘voting’ whether theirs was clean or dirty
Results might even encourage KTM to fix the problem…
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Old 07-16-2014, 10:56 PM   #776
Mike.Gail
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Location: Charlotte, NC
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Quote:
Originally Posted by CaliBerger View Post
Was thinking about the airbox problem today and wondering exactly how prevalent it is
In my industry, product registries are created that allow for easy statistical analysis and rapid contact of affected individuals when problems are detected
Relatively new here so not sure how best to accomplish this but seems as if a registry of sorts could be created by polling 1190 owners who have had the courage to look inside their airbox and ‘voting’ whether theirs was clean or dirty
Results might even encourage KTM to fix the problem…
Good idea, but the issue is in informing owners that this is something that needs to be examined. Not all of the 1190 owners are on this forum, or even another KTM based forum, so for some their first hint that there is an issue will be when the bike doesn't want to start anymore.

It's an issue of owner contact saturation.
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Old 07-17-2014, 02:31 AM   #777
2wdrift OP
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Location: Pretoria South Africa
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re

Quote:
Originally Posted by CaliBerger View Post
Was thinking about the airbox problem today and wondering exactly how prevalent it is
In my industry, product registries are created that allow for easy statistical analysis and rapid contact of affected individuals when problems are detected
Relatively new here so not sure how best to accomplish this but seems as if a registry of sorts could be created by polling 1190 owners who have had the courage to look inside their airbox and ‘voting’ whether theirs was clean or dirty
Results might even encourage KTM to fix the problem…
I dont believe KTM will fix the issue, on the 2015 bikes they might have a redesigned airbox but for us with the flawed one the only hope is to fix the problem yourself. KTM dont want to acknowledge that there is a problem because then they will have to send out a recall on all 1190's and I think that might cost them a hell of a lot, and the resulting damage to the brand name.

But this is just what I believe.
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Old 07-17-2014, 03:10 PM   #778
TDsurf
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If you have a 2013 or 2014, and you ride in dirt or dusty conditions you have a problem. The first thing I asked my dealer about was the airbox, and weather it was fixed on the 2014's. Yes it's a new part number, but the airbox is still flawed. I have not read one post from an inmate with an 1190 that rode in dirt with a stock air filter that did not have dirt in the airbox.
It's just sad that such a well respected company is trying to ignore this problem.
I guess it's all a matter of money, If they pretend that there is no problem for a year there off the hook.
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Old 07-17-2014, 06:39 PM   #779
JefRo
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Quote:
Originally Posted by wilmar13 View Post
Here is a view of my rear cyl intake valves showing the heavy deposits:



It may be hard to see but there is a LOT of gunk on the top of the valves, and perhaps this is normal because of the CCV exiting above the rear TB. It would be nice if fellow inmates can let me know if your bike's intake valves look the same next time you have a peek inside the airbox. My bike has just over 7k miles.
How did you open the butterfly valves? When I tried to open mine they were closed solid and so I turned on the ignition and was able to open them about 15 degrees but not enough to do a visual inspection as you have done. I assume that the "fly by wire" throttle control will not allow the butterfly valves to open from an external mechanical force.

It was interesting, in my case, that the rear butterfly was much more coated with gunk than the front butterfly and there was additional evidence of this by the filter media I had installed on the tops of the trumpets. Definitely there was not equal draw of air through both trumpets.

I completely concur with your assessment of dirty air completely bypassing the top of the filter at the bridge. The rubber seal on my bridge does not have a constant depth across the bridge area and would certainly not seal with the stock set-up because enough pressure cannot be applied by the two adjacent air box perimeter screws. The Uni is the only way a seal in this area can be accomplished. This is definitely one clear example of either poor design or very high production tolerance, both of which should be addressed by KTM.
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Old 07-17-2014, 07:11 PM   #780
MunK
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Quote:
Originally Posted by TDsurf View Post
If you have a 2013 or 2014, and you ride in dirt or dusty conditions you have a problem. The first thing I asked my dealer about was the airbox, and weather it was fixed on the 2014's. Yes it's a new part number, but the airbox is still flawed. I have not read one post from an inmate with an 1190 that rode in dirt with a stock air filter that did not have dirt in the airbox.
It's just sad that such a well respected company is trying to ignore this problem.
I guess it's all a matter of money, If they pretend that there is no problem for a year there off the hook.

I got my 2014 1190r the first week in May. After reading this thread I ordered the unifilter just in case. I checked the box at 1k and it was like new clean, so I left the stock filter in place.

At 2k, with a small amount of dirt riding, I checked it again. There was a small amount of dust, so I installed just the uni gasket and the stock paper filter with some grease along the bottom. I am trying to be methodical about it.

I opened the box today at 4.5k, it was clean! There were many miles of dusty dirt roads. I'm not sure why my experience is different from those in this thread? I'll keep a close eye on the filter, but for now I'm happy.


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