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October 13th, 2011, 08:08 PM   #1
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2009 Air Box Modification

All,

The first time I saw any modification was on the WORC's, Husaberg Team was using. They had removed the whole flange on the right and left radiator shrouds so that you could see through to the other side, and the air filter.

I never really felt the need to modify the air box on my bike. However, after a few stream crossings my bike wouldn't run very well for a few minutes, never could figure out why until FR 4. It finally occurred to me what was happening. I have my mid pipe wrapped so when I would go through a water crossing, the wrap would get soaked and while the water was boiling off, it would create a lot of steam, more steam than if the pipe was not wrapped. Upon closer inspection, it also became apparent that most of the induction air to the motor comes through a small opening where the fuel line goes through. Also, there was a post a while back about how high the IAT (intake air temperature) was showing on a dyno run.

So...................... I did this.





Which resulted in this.



You can see how the air flowed into the air box and onto the air filter during my last race, So Cal National Hare and Hound, 94 miles of uninterrupted ecstasy, a good portion of which was in blinding dust.

You can can also see where the air flows into the air box from where the fuel line goes through. Where as before it was obvious that most of the air was coming from the area where the fuel line goes through the tank and down to the injector.

Results. The bike definitely breathed better at higher revs, and seemed to rev a bit more freely. The intake air has to be a lot cooler with this modification.

I did not want to remove the whole flange like the WORC's team did, as I wanted to have protection for the air filter itself. And, I did not want the air box to get filled with dirt if I was sideways on a hill and some guy roosted me.

Dale
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October 13th, 2011, 08:48 PM   #2
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Re: 2009 Air Box Modification

Nice job, Dale. Has that "factory bike" look.
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October 14th, 2011, 12:04 AM   #3
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Re: 2009 Air Box Modification

cool. I might try this on my supermoto. I was going to cut a hole in the seat but didnt really want to fork out like $150 to have a spare seat for wet races.. Some holes in the shrouds can easily be taped up! Thx
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October 14th, 2011, 12:50 AM   #4
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Re: 2009 Air Box Modification

nice one dale!

regards

Taffy
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October 14th, 2011, 03:37 AM   #5
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Re: 2009 Air Box Modification

Thankyou Dale I have chased my tail with the problem you described since I had the bike. I alwasys thought it was actual water entering the airbox.
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October 14th, 2011, 05:50 AM   #6
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Re: 2009 Air Box Modification

Thanks you guys............

If you want I can tell you what bit size I used. I wasn't very "technical" about it, just eyeballed it out and went to work.

I also used a felt tip marker on the inside of the box to mark the shrouds for the bigger area up front.

One could use a bigger bit and leave a little less plastic to gain some more flow, but, again, I was thinking of ballistic protection for the air cleaner, as well as tipping over into bushes and what not as well.
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October 14th, 2011, 05:57 AM   #7
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Re: 2009 Air Box Modification

Originally Posted by DaleEO
One could use a bigger bit...........................
One could could one!

I do believe you've met the Queen ol' boy!

regards

Taffy
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October 14th, 2011, 11:59 AM   #8
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Re: 2009 Air Box Modification

I wonder if the original design was to have the air being pulled over the injector/efi to help cool it. It would be nice to know if that was the intent of the design and did it work.
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March 23rd, 2012, 08:17 PM   #9
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Re: 2009 Air Box Modification

Just a little update...........

At our recent club race while I was setting up the course and taking it down I noticed that my radiator fan never came on. This was a lot of stop and go in relatively warm weather with no wind. Before my mod the fan would easily have come on in this type of situation.

I have no way to prove it other than my observation, but, since I made this modification I have to really be abusing the clutch and not moving much to get the fan to come on. My conclusion is that the motor is pulling in cooler air, that by itself is going to lower temps, as well as the IAT sensor seeing cooler air will richen the mixture further cooling the running temp.

Dale
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September 22nd, 2018, 11:09 PM   #10
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Dale, I don't see the pictures of your airbox mod. Can you try again or is something wrong from my end
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