Airbox mod for skint

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sabestian · #1 Post by **sabestian** » Sat Apr 21, 2007 9:32 pm

Ok, here it is: 10 pounds, 15 minutes airbox mod for tight All the benefits, none of disadvantages, at fraction of a cost. Sound is a killah (chirping... growling... extasy). The bike seems to rip the asphalt with every piston move. It is like hitting the road with a rubber mallet.

Engine transformed, clean acceleration from tickover.

I had only 5 miles test drive , will try to escape tomorrow. Cannot wait.

It works - how could it not? Will see about long term engine reliability

I simply removed ALL airbox parts apart from bottom plate (base) - top lid, filter, ducts, hoses, everything. This saved me a nightmare work (although rewarding) of fabricating a plate. Socks fit tight on the trumpets. Very tight between them (I needed to trim them a bit - 1mm each).

Still need to sort the engine breather filter (available ones double the cost - out of the question ). Perhaps Hansie's baby-bottle-style would do? But I don't like copying. Will see.

If anyone dares to follow me on this mod, please make sure that the socks fit tight around trumpets at the bottom of the airbox as there are additional draining canals, and also there is another opening (slipper clutch - not sure what for). With the socks fitting tight, everything looks sealed at the moment, will monitor just in case tho.

Sorry for a poor quality picture (posting from MDA).

Or click me

Gio · #2 Post by **Gio** » Sat Apr 21, 2007 10:05 pm

Doesn't matter about the pic quality.

I would raise one concern tho and thats a separate foam cover over each trumpet. if they differ in density then maybe one would run leaner than the other. Also (IMO) dirt will collect faster on the leading one which will affect breathing.

You could have fitted airbox clips to the plate to clip the covers to it and make just one filter fit (ala the Renegade type)

sabestian · #3 Post by **sabestian** » Sat Apr 21, 2007 11:19 pm

You just wanted to p1ss on my fireworks, admit it Gio.

Stokesy · #4 Post by **Stokesy** » Sun Apr 22, 2007 7:34 am

Sounds good Seb
Can get to the link though!!!!!!!!!!!!

Hansie · #5 Post by **Hansie** » Sun Apr 22, 2007 8:47 am

Looks smart Sabestian!
Be sure there is a metal support in the filters so that they wont get sucked in at high rpm's.

Forgoy to patent my baby bottle so....
I use a longer tube for the breather and routed that to the frontsprocket : free chain oiler! Common thing for Renegade airkits.

sabestian · #6 Post by **sabestian** » Sun Apr 22, 2007 11:29 am

Hansie wrote: Be sure there is a metal support in the filters so that they wont get sucked in at high rpm's.

That's what I worry the most at the moment (apart of setting the tank on fire, that is

). I tried to use cable-ties to keep the socks secure but they spoil the seal against the airbox base.

To place the socks onto the trumpets I needed to detach them from tthe base. There is no way to remove them without tearing them apart.
I'm not sure if the suction is strong enough to do it.

I don't think I can think of a metal support for the socks that would be easy enough for me to fabricate...I'm hoping to be in B&Q today, perhaps I'll get an aluminium mesh that would be good. But the sharp edges are putting me off.

Nooj · #7 Post by **Nooj** » Sun Apr 22, 2007 5:25 pm

I use a longer tube for the breather and routed that to the frontsprocket : free chain oiler!

I did that, but it got chewed up, then blocked which caused oil to spew out everywhere and make the clutch slip like you wouldn't believe. Nice and easy to get into neutral at the time though.

johnl · #8 Post by **johnl** » Wed Apr 25, 2007 7:21 pm

Put a filter/collector beneath the box. Works very well for me and cheap

Johnl

Gio · #9 Post by **Gio** » Wed Apr 25, 2007 7:29 pm

sabestian wrote:You just wanted to p1ss on my fireworks, admit it Gio.

Oh dear no, I think its just a concern (maybe I've ridden Honda's to long, with all their over engineered bits)

sabestian · #10 Post by **sabestian** » Thu Apr 26, 2007 6:48 am

OK, there are some good and bad news.

Everything is still nice and secure, no problems there at all.

Bad news is that although I set the idle mixture (the bike idles smoothly at 1400rpm) it still tends to stall sometimes.

It can idle for 5 minutes perfectly but then after a ride, it can stall on deceleration (like there was no fuel - power drops down to the point of stalling but not a sharp cut-off). Sometimes it stalls when waiting for lights to change.

Never happens on steady throttle while riding (motorways etc) or on higher-than-4000rpm.

All the connections, switches seem to be fine, was running on fuel from different sources, so that is not the case either. Doesn't feel like electrical problem (power drops gradually, like the engine was starving or chocking).

Strange thing is that those power-cuts last for couple of secounds (1-5) and then everything gets back to normal.

I usually can 'power' through them adding/blipping the throttle.

Sorry for a long read

But I found it therapeutic

I'll need to un-do the mod and see if it disappears...

Hansie · #11 Post by **Hansie** » Thu Apr 26, 2007 7:40 am

At decall the vacuum indside the airintake is huge, maybe they get partly sucked in(dented) and block airflow?
A dented airfilter blocks air.

Thats all I can think off.

paddyz1 · #12 Post by **paddyz1** » Thu Apr 26, 2007 8:26 am

Hansie wrote:At decall the vacuum indside the airintake is huge, maybe they get partly sucked in(dented) and block airflow?
A dented airfilter blocks air.

Thats all I can think off.

I don't think the vacuum is on the airbox side of the butterflies as they will be closed (assuming throttle is fully backed off)Dont know about backing off slightly though.

Since I have done my mod I have very low end flat spot around 2000/3000K but it ticks over fine and feels great anywhere else. What chip have you got. I have a renagade chip that I brought off treetops, It came with the ECU so I just swap over the unit rater than the chip. He told me that he loved playing with the PC111 (which I believe you have). I assume he had adjusted the trim pots on the unit (I dont know anything about these as of now but I am learning).
If you have a standard chip then I believe the trim pots are disabled.
If you have had an after market chip fitted to your original ECU then I think you will need to adjust the trim pots

Have a look here

http://www.apriliaforum.com/forums/show ... =trim+pots

sabestian · #13 Post by **sabestian** » Thu Apr 26, 2007 10:38 am

I have a stock chip.

I was checking the way the filters behave with a tank up, they seem to be v stable (don't get dented or sucked in). I don't think this could be the problem (it may be different when there is a lot of engine braking while on the move

though). But it wouldn't die on tickover... And that feels the same.

I checked the map I'm currently running to look for lean/reach spots in the low range area but there is nothing suspicious there. Previously I manually edited map this way, smoothened the curve and had great results. But - again - I don't think this could be an issue, 'cos it wouldn't affect idling.

There may be something different going on and the timing with the airbox mod may be just a coincidence. How am I going to find it though? If only it was always there. It seems to come and go. Frustrating!

sabestian · #14 Post by **sabestian** » Thu Apr 26, 2007 10:43 am

Hansie wrote:At decall the vacuum indside the airintake is huge, maybe they get partly sucked in(dented) and block airflow?
A dented airfilter blocks air.

Thats all I can think off.

I think they would get sucked in when there is a load on the engine rather... But I will get them strengthened with a metal mesh. One day

paddyz1 · #15 Post by **paddyz1** » Thu Apr 26, 2007 10:48 am

What you need are the 54mm throttle bodies and the ECU that I got off tree tops. They would match the PC111 that you got off Tree tops.

BUT..........It would be far easier for you to send ME

the PC111 and let me have all the problems instead