Your video (part 2) stops before it shows how you fit the 90 on to the throttle body. You mention using a razor to cut the rubber throttle body coupling to fit the 90, but it doesn't show it in any way. Can the rubber coupling be removed without removing the air box and the 90 clamped directly to the throttle body? Thanks! Edit: nevermind, I fond the other thread right here http://www.cafehusky.com/threads/how-to-change-the-tr650-air-filter.40519/ there's images of the gromet/coupling removal. Starting on this soon.
Check the bottom half of this page http://www.cafehusky.com/threads/pottering-around.39580/page-2 to save worries the air box body dropping onto the fuel rail, making spacers etc.
I did the pod mod following the examples of several of the contributors before me. I did the hot knife cut per Big Dog and as with Glitch oz I removed the upper part of the rubber grommet so the air box could sit on it. I used an X-acto knife with their chisel accessory. It's very sharp and I was able to easily make a clean cut around the grommet flush with the air box base. I also cut 1 1/8 inch off one end of the 90 degree hose so the uni filter can sit lower the air box. In total it took about 2 and a half hours. Thank you to all who pioneered this fix.
I just finished doing it tonight and ended up cutting some off both sides to get the filter to sit inside completely so the air box could come back together. I need to find a way to seal it now, though. What have others used? i thougt of just caulking it - it'd be easy enough to peel off and recaulk every time I need to open and clean it. Also, though I've never been off road with mine except once (and there was no dust) the throttle body was coated in soot.
Followed Big Dog's suggestion and used Gorilla tape. Duct tape is not as "sticky" but would probably work as well.
Just read through the entire thread. I must say how glad the POD MOD has worked out for those who have choosing that path. Having this forum makes owning the bike that much better, so many fantastic ideas bounced around. They say necessity is the mother of invention. The engine failure due to poor inlet air filtration led me to the POD MOD idea. Getting to bounce ideas around with Charlie was great. Spending time working on the bike was fun too. For the record, both modified bikes are running great. I have found no trace of dust in the throttle bodies. Now....what's next. Njoytheride BTW, what does POD MOD stand for ????
After reading as much info on the different fixes for the air box problem I have decided to do the Pod Mod. My Terra has 4750 kilometres on the clock having had 2000 of them when I bought it. I have only just had a chance to take it off road last weekend so most of the work has been in clean air. The interior of the air box as expected was dusty and TB was dirty as well. I am soooo glad you guys found and sorted this problem. View attachment 43294
Is anyone else having oil blown into the air box from the crankcase breather? I just did the Pod Mod and replaced the swollen crankcase breather hose at the same time. I'm now having oil blown out of the breather element
I missed that part. Good idea! I'll be going back into the bike once I get my new air box lid (messed up the first one). I'll have to move the breather while i'm in there
I went back and did my POD MOD again. I wasn't happy with how I cut the air box lid the first time. I ordered a replacement from Halls. FYI the new lid had a KTM sticker on it.... I also wanted to add a support so the bottom of the air box wouldn't sit on the fuel rail. I made a "seat" out of a 3" PVC pipe cap. I used a 2.25" hole saw in the drill press and a band saw.
Dry fit. The "spacer" float around a little bit on the throttle body but it's enough to support the air box. After a nice evening ride I'm about to crack open an Imperial Stout and go have a look make sure the spacer isn't sagging or moving around too much. I will report in the morning
I I changed the screws holding the fuel injector, long enough to pass thru' the airbox, with neoprene roofing washers to support the weight I also used a 2mm thick neoprene rubber cover approx 300mm x 300mm cut-out for the fuel filler to tay over the airbox joint, this also had the effect of quietening the throb & reducing weather leakage into the airbox etc etc
I would like to do a pod mod change my bike but I was wondering dare I to do it. If I do it, so I lose the warranty from the engine, bike guarantee otherwise remain. Here in Finland we have two years warranty on motorcycles. How long do you have guarantee on motorcycles?
