I thought the fram fliter for the KLX had the same issue as well. Go to put the cover on and it sits 2mm above the surface. Im changing my oil tomorrow and bought the fram, will see how it goes.

 

An the plot thickens.. So I am coming up to oil change time and stopped by my local honda/suzuki dealer. Got my oil and asked for a filter. All they had was K&N. Thought to myself let's try this one more time. I haven't done my oil but just looking at it is am think it will fit.

Differences

First off the problem filter is made in Korea
New filter made in China
Problem filter was 2 mm from fitting. If you look at the new filter on right the spring recession is deeper.

I will update later today but as far as I see China got it right.

http://i.picresize.com/UQgt

http://i.picresize.com/UQgS

 

Oil change is done. Filter fit fine. Something to watch out for.

 

As long as nothing blocks the flow all's good. Remember the old Honda XR/ATC200 engines? No oil filter, a couple screens, but no actual filter. They ran forever!

 

True but the problem with the other filter being 2 mm taller you can't put the cover on.

Speaking of flow has anyone noticed the oil travel? One passage into the housing and two out. One to bottom and one to top end of course but nothing sealing the two outlets on cover to housing. In other words a % of oil can bypass the filter.

 

You got a point there...

Never noticed, will have to look.

 

Hey Dustin, I finally got around to changing my oil last week. First time since you sent me that filter. The one that came out happened to be the same size as the one you sent me. I did use your filter in my bike with no isuues. But, before putting it in, I went to Walmart and bought a Fram CH6015 which is for our bike. Plus the Fram comes with the cover O-Ring which is nice. That Fram filter was 2mm shorter than the K&N you sent me. When I installed the K&N you sent me, I was able to close the cover cap by turning the 2 bolts with my fingers, no wrench. So I know for sure, it didn't bind or crush. Maybe my spring is weaker or shorter? I don't know. I did take pics comparing the two. You can see the difference.

 

Interesting.. that leads me to believe it just a little difference clearence issue. My cover is probably a touch fatter and the case a touch shallow. Typical mass manufacturing. Although I didn't try to finger the bolts in as my Kawi filters allow to cap to pop right on. The new k&n fit just like the kawi.

Strange but glad it worked on your bike.

 

So what your saying is, the K&N filter you just put in fit ok? I did notice that the one you sent me was made in Korea. I had K&N filters made somewhere else. Don't remember, but it wasn't Korea. Maybe it's them? But then again, yours fit in my bike. Try the Fram CH6015. $5 bucks at Walmart, Auto Zone, Advanced Auto, etc, and comes with the o-ring for the case cover. I gotta say, It looked like a solid, quality built filter. I change my oil and filter every 1,000 miles or so, so I'm ok using Fram filter. I've heard they aren't that great (forum rumors), but I beg to differ. Those rumors come from unreliable sources, period. Never heard this working in the MC industry all my life. I don't know the micron specs on these Fram filters, but for sure it's better/finer than the SS reusable screen filters by far. Plus changing oil often (1,000 mls) on a engine that's not being overly pushed hard, it's perfectly fine. I change oil often cuz I still have a 30 gallon drum of Bel-Ray oil to use up.

Anyway, pay attention to where the filters are made. We may find that the different factories making the same filter, are finishing off with different specs as far as size. There's a reason the Fram filters are 2mm shorter than the K&N filters for same bike. Someone's wrong, and since yours didn't fit, I'm thinking K&N needs to retool something. Maybe the press jig is starting to wear, and it's getting passed quality control "IF" there is any. I'm still interested in finding out about this. So keep me posted.

 

I'm with Werloc. Filters (and oil) somehow call for an undeserved amount of passion from motorcyclists.
Micron specs aren't generally published and that's probably a good thing as the rating of the filter media the manufacturer chooses is a compromise between filter life, filter size and acceptable pressure drop. Too much pressure drop across the filter (due to clogging or cold start) calls for a larger oil pump and can push oil through the by-pass without being filtered at all. Proper fit can be much more important.