After my second piston broke I bought another K&N. I had no idea they came with a foam filter as this bike was robbed of it's original before I bought it and I got no owners manual. I ran 20 miles, changed filters and another 20. Cleaned and oiled with K&N cleaner and oil. Greased the threads where it screwed on... Same problem. 270 to 400 miles and the piston skirt broke off on the intake side and many times the rotary valve was worn on the leading edge it was razor sharp - literally. This was on a bike that was the most reliable dirt bike/enduro bike built to date.
When I finally figured it out I went over 3,300 miles in all dirt and did a tear-down with almost no wear.
Silt passes through the fibers. So, the quick solution is to run a foam wrap. Why not just run a UNI? Less restrictive than two filters in my opinion.
Quick test: Take off your K&N and run your index finger in the bell of the carb. If you have ANY dirt (silt or film of brown color) it is passing dirt and your intake skirt will likely break off. Use a Q-Tip if necessary as the contrast is better with the dirt on white.
I am probably K&N's worse customer but I have $1,100.00+ in bills and so much down time (before UPS and FedEx times) so I will continue to steer people away from their product. Even their new products pass silt, I have a Banshee I bought that wore out in about 40 hours. It hooked a ring on the exhaust port due to excessive wear. That is uncalled for in todays times.
