• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Step by Step air box and air filter modification

mag00 said:
It is possible. I did it, http://youtu.be/a_5mKsVW_-Y and part 2 is on the same utoob channel.

I do not think you have to pull the right side panel.

Another has done it in under 2 hours, with lollygagging included.
Click to expand...

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.
 
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.
 
CRSAM said:
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.
Click to expand...

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
 
V8Astro said:
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
Click to expand...

Yes, I got mine fixed up good now. Page 3 of this thread just in case you haven't already seen it.
 
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.

20140708_144853.jpg

20140708_144727.jpg

20140708_144848.jpg
 
V8Astro said:
.

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.

Nice thinking....did you glue pvc spacer to airbox...or just a dry fit? I may follow your ideal. Thanks
Click to expand...
 

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 :)
 
mag00 said:
I'm with you on this. As much as I admire the work going into the new 3d housing etc, there are inherent problems that have not been addressed. One that I have only mentioned a little is the actual fastening of the parts being modded. Talk of glue makes me cringe. When I set out to do the mod, I had every intention of using a plastic welder. Glue on this plastic will only stick short term. Plastics gas off, and that will release ANY glue or epoxy that has not chemically bonded to the parent material, with the parent material chemistry. You can take that right to your repairman, after you have been to the bank. I have tried a host of glues, and did not find the one that fuses/bonds/melts the parent material.

And let us not forget how plastic warps over time. That and the rubber seal getting brittle. You are going to have to do the Uni Pod Mod anyway, or buy a new airbox.

I love the ingenuity of the project, but it is far more work, far less effective and possibly could cause a catastrophic failure out in the wild. And if you dump your bike, and crack the airbox, you are still SOL. At least with the pod, you can strip your bike naked as Dr. Z has, and still drive knowing you are getting clean air into your engine. These are 100k mile engines if you take care of them. 20k if you don't.


(hope you don't mind being a doctor Charlie) :thinking:
Click to expand...


I like the 100,000 miles, that's 163,000klms
 
V8Astro said:
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 :)
Click to expand...

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?
 
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