How To: Make An Airbox Mud/Splash Guard - (Photos) - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 2 Old 07-08-2010, 10:00 PM Thread Starter
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Black Lab's Avatar
Join Date: Mar 2008
Location: Mount Desert Island, Maine
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How To: Make An Airbox Mud/Splash Guard - (Photos)

Airbox Splash Guard for a 2007 DL-650.

Before I departed for last weekend's trip, I had to do some maintenance to my bike. I mounted up a new set of Shinko 705 tires, changed the motor oil, changed the fork oil, adjusted my Race Tech emulators, and swapped out my air filter.

When I separated the top portion of the airbox and flipped it over to inspect it. I noticed quite a bit of dirt had collected along the inside flange of the lid, (the area where the gasket from the airfilter sits.). Unfortunately, before I took a photo of the grit, I cleaned it off. But, in the below photo, you may be able to see evidence of "muddy water" residue that has dried on the underside of the airbox lid.

I have modified my motorcycle. I do not have any of the OEM fairings on the front of the bike anymore. Because of this, water has a freer pathway where it can more easily get driven back towards the airbox. Previous to this particular airbox inspection, (With the OEM fairing configuration), I had never found dirt that had gotten "forced" between the lid and the bottom portion of the airbox before.

I cleaned the grim out of the flange and decided to add some protection to the airbox.

Using a pair of scissors, I cut a piece of 3/32" sheet rubber I had scrounged from work.

I then slid the piece of rubber, up behind the snorkle tube and fastened it in place with two zip-ties.

I felt, I now had an effective "mud flap" to deflect debris from infiltrating the seam between the lid and the bottom of the airbox.

Then I looked at my air filter, (I make up my own: Info HERE), and remembered the "mud stain" on the underside of the airbox lid. I thought, "Okay, I have taken care of the seam of the airbox, but what about the snorkle too?"

I started poking around the front end of my motorcycle and came up with a solution that works for me.

Just behind where the steering stem passes through the bottom portion of the motorcycle frame, there are two holes that are drilled and tapped for a 10mm bolt. The left hole is used to secure a "clamp" that holds part of the wiring harness to the bike.

I removed the harness clamp.

Using a tape measure, I figured out what an appropriate width would be for another rubber, "mud flap" and also laid out where I needed to drill holes through the rubber sheeting.

(I really needed a hole punch for doing this. Drilling through rubber sheeting isn't the appropriate technique for acquiring a hole.).

Next, I cut off a piece of steel strapping I had hanging around......

.....and drilled two holes through it that corresponded to the threaded holes in the bike frame.

I "dry fit" the steel strap by threading the bolts through it and into the bike's frame. Everything was "A-O-Kay".

I then, slid the bolts through the rubber, "mud guard"..... (The "silver goo" that you see on the rubber is "Never-Seize". I am using Stainless Steel machine bolts that are being threaded into the aluminum frame. Some corrosion is inevitable, the "Never-Seize" will help with that.)

....and bolted the unit to the bike.

I tucked the "mud guard" up into the space over the radiator and let it hang down behind the cross member of the crashbars I made for my bike. I was looking for a "natural drape" of the rubber guard.

When I was satisfied that the mud guard was in its proper place and would do its intended job, I marked where I needed to "drill" two more holes.

As I said before, drilling through sheet rubber is not a good solution. As the drill bit spins through the rubber, it tends to "fetch up" and twist the rubber around its body and also, pulls the drill bit, in a sort of uncontrollable fashion, away from you. I decided on a safer solution because I was so near the radiator. I didn't want my drill bit to "pull" itself through the rubber and right into the radiator!!!

I grabbed a mill file off of my workbench along with my propane torch. I heated up the end of the file......

...and "melted" four holes through the rubber sheeting.

Using zip-ties, I fastened the bottom edge of the mud guard to my crashbars.

Once the mud guard was fastened, I cut the excess rubber off of the bottom edge.

Here is the finished, "Airbox Mud Guard".

Finally, I used a zip-tie to secure the wire harness to the anchor tab on my radiator.


2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
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Last edited by Black Lab; 07-08-2010 at 10:14 PM.
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post #2 of 2 Old 07-09-2010, 01:44 AM
henerythe8th's Avatar
Join Date: May 2007
Location: Ice Harbor, WA
Posts: 1,516
Whatever works!

A technique for drilling a hole through rubber that works is to sandwich the rubber between a couple of scraps of wood clamped tight, and then drill through . . .

L2V -- she's a stocker!...and gone...
2011 MG Stelvio
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