drzcharlie
Husqvarna
Pro Class
In the States it is a 1 year warranty. If you are worried about it, you can get an airbox cheaply enough to have a spare if you need to take it back for warranty work with the stock airbox intact.
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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 The previous version was outdated and no longer supported.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
- Thread starter drzcharlie
- Start date
Husqvarna
glitch_oz
Husqvarna
Pro Class
I think who ever did the pod mod was faced with the same dilemma.
I did mine long before actually registering the bike.
2yr warranty here in AUS
drzcharlie
Husqvarna
Pro Class
I think not doing it will force your bike into a warranty situation with the top end gone from ingested dust and grit. Just my two cents.
Geeza
Husqvarna
AA Class
Started the air box mod today, like to say thanks to all the originators and contributors to this mod, wealth of great information, also stole a couple of your photos! 
First step was to modify the air box door. Have started a thread on this:http://www.cafehusky.com/threads/air-box-door-mod.53908/
Now the pod mod, cut the top of the air box - no problems, throttle butterfly was nice and clean as expected as I don't do dirt!
I have chosen to cut down the rubber grommet around the throttle body so that it continues to support the air box and keep it off the fuel rail.
To remove the rubber grommet from around the throttle body I first loosened it with a plastic scraper then removed the bolt from the coolant reservoir so that the rear of the air box could be lifted up enough to get the grommet out. (drzcharlie photo)
Wanted to cut the grommet down to the top of the gap between bottom and second ring. (mag00 photo)
To do this without cutting off my fingers
, also to ensuring it was square and smooth I put the grommet over a piece of scrap 57mm pipe and used the grinder with a "flapper" disc on it.
result:
cannot post more than 4 images - don't know why so will add another post
First step was to modify the air box door. Have started a thread on this:http://www.cafehusky.com/threads/air-box-door-mod.53908/
Now the pod mod, cut the top of the air box - no problems, throttle butterfly was nice and clean as expected as I don't do dirt!
I have chosen to cut down the rubber grommet around the throttle body so that it continues to support the air box and keep it off the fuel rail.
To remove the rubber grommet from around the throttle body I first loosened it with a plastic scraper then removed the bolt from the coolant reservoir so that the rear of the air box could be lifted up enough to get the grommet out. (drzcharlie photo)
Wanted to cut the grommet down to the top of the gap between bottom and second ring. (mag00 photo)
To do this without cutting off my fingers
, also to ensuring it was square and smooth I put the grommet over a piece of scrap 57mm pipe and used the grinder with a "flapper" disc on it.result:
cannot post more than 4 images - don't know why so will add another post
Geeza
Husqvarna
AA Class
Refitted the grommet around the throttle body:
Refitted the reservoir bolt before I forgot about it!
- happy with how the air box sits, the grommet helps centre the air box on the throttle body
- the grommet stops the air box from moving down onto the fuel rail
- have clearance between the air box and the fuel rail
- did not have to enlarge the hole in the lower air box around the throttle body
- I have just shy of 15mm on the throttle body for the silicone hose to clamp on
Refitted the reservoir bolt before I forgot about it!
engineerk9
Husqvarna
AA Class
Possibly without the airbox mod the engine may not last the 2 years, & arguably wouldn't be repaired under warranty conditions
nev..
Terrarist
I know at least one engine in Australia was getting a warranty rebuild after a dusty airbox caused the engine to fail.
Was "Chuffa" one?
Karen Ramsay's bike was definitely one that got rebuilt.
We need a list?
Chuffa
Husqvarna
Pro Class
Nope. I'm still topping the oil up.
Geeza
Husqvarna
AA Class
One option when refitting the cut air box lid to add the strength back into the top cover.
Used a piece of 3mm galvanised steel, 4 panel clips and some self tapping screws with large washers.
Made the gap 3mm wide so that I can fit a seal between the two halves.
One more hose clamp to fit, bit of paint on the bracket, fit the seal and its finished.
Used a piece of 3mm galvanised steel, 4 panel clips and some self tapping screws with large washers.
Made the gap 3mm wide so that I can fit a seal between the two halves.
One more hose clamp to fit, bit of paint on the bracket, fit the seal and its finished.
Geeza
Husqvarna
AA Class
Good idea with the D-zus fasteners. I work in the aircraft industry and was hoping to use something similar, just don't have access to a parts bin at the moment
Maybe in the New Year.
drzcharlie
Husqvarna
Pro Class
Geeza...I love it. Great idea. Hey did you get your LC2 yet?
Geeza
Husqvarna
AA Class
Thanks for the feedback. LC2 not yet, snail mail from the States, hopefully soon.
Geeza
Husqvarna
AA Class
An option for cutting the silicon hose/elbow square and neat.
Just need a hose clamp, sharp knife, set square and a piece of steel tube with a square cut end that is a snug fit in the hose.
Work out how much you want to cut off, push the steel tube into the hose and ensure the square end is protruding from the hose. Loosely fit the hose clamp around the hose then use the set square to measure down from the end of the steel tube to the clamp thus ensuring the hose clamp is the same all the way round. Tighten the clamp and recheck the measurement.
Take a nice sharp knife and using the edge of the hose clamp as the cutting edge/guide cut the silicone hose.
Have a safe and enjoyable Christmas, ride safe - stay safe.
Just need a hose clamp, sharp knife, set square and a piece of steel tube with a square cut end that is a snug fit in the hose.
Work out how much you want to cut off, push the steel tube into the hose and ensure the square end is protruding from the hose. Loosely fit the hose clamp around the hose then use the set square to measure down from the end of the steel tube to the clamp thus ensuring the hose clamp is the same all the way round. Tighten the clamp and recheck the measurement.
Take a nice sharp knife and using the edge of the hose clamp as the cutting edge/guide cut the silicone hose.
Have a safe and enjoyable Christmas, ride safe - stay safe.
drzcharlie
Husqvarna
Pro Class
Leave the box in. It affords you significant protection from water intrusion.
mag00
Husqvarna
Pro Class
The airbox also holds the panels and keeps hot air from the engine from going directly into the intake.
I looked into custom frame to hold the panels, and hoping for more room for tools etc, but not really feasible. It could be done I suppose.
It removes easy enough for the mod and reinstall, but doesn't have to be removed to do the mod.
I looked into custom frame to hold the panels, and hoping for more room for tools etc, but not really feasible. It could be done I suppose.
It removes easy enough for the mod and reinstall, but doesn't have to be removed to do the mod.