Air box door mod

[Geeza]

Decided to modify how the air gets into the air box.

Part A



1. removed the air box door (3 torx screws) and then removed the air filter from the filter frame.



2. removed the filter frame from the back of the air box door (3 phillips screws).



3. marked out and cut the filter frame and the air box door. On the back of the air box door are 4 location lugs for the filter frame, I cut the opening a few millimetres inside these lugs, this ensures the door will hold the filter frame in place when refitted to the air box.

 

[Geeza]

Part B

4. replaced the filter with a piece of perspex (protective paper still on the perspex)



Air box door opening with filter frame in place. Perspex blocks off the airflow from the factory air intake.



Air box door temp fitted. Will fit some filter foam and some wire mesh between the filter frame and the air box door to act as a pre filter (in the process of doing the pod mod).




What am I trying to achieve with this mod - hopefully more airflow into the air box.

Will post more images once finished.

 

[FabOneUp]

 

[jawjo]

Any updates, keen to see pics

 

[Geeza]

Part C

Glued some 3mm neoprene sheet left over from another job onto the perspex sheet to act as a seal on the inside of the air box where the original paper filter sat.


Cut some 25mm filter foam 10mm larger than than the apeture in the filter frame. It is a snug fit in the filter frame hole.


Filter door refitted, have run the engine and you can feel the air being drawn into the air box. Once the bike is back together and been for a run I may look at fitting a stainless steel mesh panel in front of the foam.


Put an off cut of the foam into the original intake so it matches the look of the new door intake.

Happy with the look of the new intake. Will be interested how it will sound once the pod mod is finished (still waiting for the courier to deliver pod!)

 

[FabOneUp]

I like it! I would have to add a front deflector panel of some sort (if there is room) with an opening from the bottom for my climate. Our last couple of trips we went through quite a bit of rain. Well done Geeza. Keep us up to date on how it works for you.

 

[danketchpel]

I like it! I would have to add a front deflector panel of some sort (if there is room) with an opening from the bottom for my climate. Our last couple of trips we went through quite a bit of rain. Well done Geeza. Keep us up to date on how it works for you.

I have been running my bike with the door completely removed after doing the Pod Mod. It's kinda loud with a lot of intake honk. I've thinking about how to do a baffle door to serve to keep out the rain and to lessen the noise. I was watching this development to see how it panned out.

I like the work Geeza did, it's clean looking.

My thought on a door baffle would be along the lines of what FabOneUp posted, maybe spaced forward about 1/2" and only open on the bottom. I'd keep the stock opening so you are really just adding to it.

I'm curious to hear Geeza's opinion on the sound. The foam might muffle the honking some.

 

[Clete]

Geeza, are you running the Pod Mod, or the 3D printed filter frame?

 

[Geeza]

Geeza, are you running the Pod Mod, or the 3D printed filter frame?

I am in the middle of carrying out the pod mod.

 

[PaulC]

Geeza Great Work! Im gonna stick my neck out here... but your mod might be good enough coupled with the standard aussie foam unifilter. The reason being, you Will drop a fair bit of performance doing the pod mod. As I have. The only problem I can see is riding in the rain (at Hway speeds) for extended periods. Anyhow good job M8

 

[nev..]

Will drop a fair bit of performance doing the pod mod.

Do you think? I haven't noticed any loss on mine. I haven't heard too many people complaining about performance after pod-modding.

The only problem I can see is riding in the rain (at Hway speeds) for extended periods. Anyhow good job M8

Also, think about drainage. The area of the airbox behind the door is the only part of the airbox which doesn't have any drainage.

 

[danketchpel]

Do you think? I haven't noticed any loss on mine. I haven't heard too many people complaining about performance after pod-modding.

I haven't noticed any decrease in performance. Though I do think changing the intake tract length (lengthening) may have a slight affect on the very top end performance. Normally lengthening the tract will increase torque at lower rpms and shortening it is better for top end, basically raising the torque curve.

Depending on the elbow used it can decrease performance if it's too restrictive as I found that out with my ABS approach, it definitely decreased upper rpm performance.

The larger smooth bend silicone elbow seemed to fix that problem, though my bike doesn't wind out with a ferocious top end like a sport bike, I don't really care. I want the torque peak lower down in the 4-6k range where it is now. I'm also not sure I've nailed the AFR for the the 7-8k rpm range yet either.

Also, think about drainage. The area of the airbox behind the door is the only part of the airbox which doesn't have any drainage.

I've thought about adding a drain hole in the airbox on the right side.

 

[drzcharlie]

I've got two holes. Both drilled in the bottom of the air box at it's low points.

 

[Geeza]

Geeza Great Work! Im gonna stick my neck out here... but your mod might be good enough coupled with the standard aussie foam unifilter. The reason being, you Will drop a fair bit of performance doing the pod mod. As I have. The only problem I can see is riding in the rain (at Hway speeds) for extended periods. Anyhow good job M8

Thank you for the feedback

I had some concerns about the potential for the pod mod to restrict the airflow into the throttle body, hence the mod to the air box door to increase the amount of available air inside the box.
Also I have been trying to fit a 76mm to 56mm reducer elbow into the air box so the it acts like a ram intake into the top of the throttle body, coupled with the American uni filter with a 76mm outlet.

Unfortunately I have not been able to achieve this so have resorted to the 57mm to 57mm elbow, just made sure it was a good quality silicone hose and metal joiner/coupling. Now using the American uni filter with a 57mm outlet as the original pod mod guys did.

 

[Geeza]

I'm curious to hear Geeza's opinion on the sound. The foam might muffle the honking some.

Have not done the pod mod yet, still waiting for parts so I put the bike back together and went for a ride - wow what a difference!

Rode it without the foam and yes it has a definite honk, refitted the foam and it does muffle the noise to an acceptable level.

I was hoping for some improvement with the mod to the door but the change in the bike is above my expectations. The throttle is more responsive, she definitely pulls harder and has a lot more go.

My mate took it for a spin and asked if I had de restricted the bike; the difference is that noticeable (I have the learner restricted version).

Went for a 150k ride and the bike was still performing the same at the end of it, the ecu has not spat the dummy with the extra airflow.

My suggestion to anyone thinking about doing this, take off the air box door and remove the paper filter if you still have one - go for a ride - see if you notice a difference - if yes you have to do this mod to the air box door.

 

[engineerk9]

Geeza Great Work! Im gonna stick my neck out here... but your mod might be good enough coupled with the standard aussie foam unifilter. The reason being, you Will drop a fair bit of performance doing the pod mod. As I have. The only problem I can see is riding in the rain (at Hway speeds) for extended periods. Anyhow good job M8

You lost performance with the pod mod ?? Please tell us more ?

 

[drzcharlie]

I think everyone I have ever seen comment on the Pod Mod has experienced a positive gain in performance doing the Pod Mod. But, every bike is different.

 

[engineerk9]

I haven't noticed any decrease in performance. Though I do think changing the intake tract length (lengthening) may have a slight affect on the very top end performance. Normally lengthening the tract will increase torque at lower rpms and shortening it is better for top end, basically raising the torque curve.

Depending on the elbow used it can decrease performance if it's too restrictive as I found that out with my ABS approach, it definitely decreased upper rpm performance.

The larger smooth bend silicone elbow seemed to fix that problem, though my bike doesn't wind out with a ferocious top end like a sport bike, I don't really care. I want the torque peak lower down in the 4-6k range where it is now. I'm also not sure I've nailed the AFR for the the 7-8k rpm range yet either.




I've thought about adding a drain hole in the airbox on the right side.

I drilled a 6.00mm diameter hole in the lowest point of the airbox, just infront of the throttle body, just incase some rain water entered

 

[engineerk9]

I think everyone I have ever seen comment on the Pod Mod has experienced a positive gain in performance doing the Pod Mod. But, every bike is different.

I certainly gained a noticeable gain in torque with the pod mod, don't know about full throttle, I rather like the deep induction roar when the engines pulling hard, the slightly longer inlet pipe stabilises airflow acting like a ram tube, benefits low revs & torque

 

[PaulC]

You lost performance with the pod mod ?? Please tell us more ?
engineerk9, Dec 14, 2014 House Keeping


???... Even tho its floored The Husqvarna R&D department has tuned (or did tune) the air box for you.