Four Airbox Mods - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 18 Old 03-21-2016, 11:44 PM Thread Starter
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Four Airbox Mods

I made the following mods to my airbox and thought I'd share it with the group if anyone is interested;
  1. Snorkel Farkle
  2. Breather Baffle
  3. Catch-Can
  4. Bee Blocker

1) Snorkel Farkle: I installed a piece of gray PVC (thick walled) conduit under the inlet snorkel to redirect the flow of air inside the airbox. In this side view you can see it wedged under the inlet and it rotates the snorkel so that the nozzle inside the airbox is more parallel with the lid. Its wedged in there pretty tight and I put a light coat of silicone grease so it doesn't wear into the nozzle.



Inside the lid, here is what the inlet snorkel looks like without the mod.



Notice that the inlet tubes direct air right at the reinforcing ribs in the lid of the airbox thus creating a lot of turbulence. The metal grid with holes under the air filter is actually a flow straightener to convert turbulent flow to laminar flow which is better for the engine as air enters the intakes. The Snorkel Farkle changes the angle of the inlet flow thus reducing turbulence, here is picture of the inlet with the mod installed;



See how the inlet is now parallel with the top of the airbox and not aimed at the ridges in the lid. Based on other airbox mods I've read about it seems that the engine is not really constrained by inlet flow (e.g. removing the snorkel completely makes no difference other than making it annoyingly loud) but I am hopeful that this mod might help if it reduces turbulence on the air inlet side.

Continued in next post...
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File Type: jpg Week71 009A.jpg (77.0 KB, 765 views)

Pink Floyd: And did you exchange a walk-on part in the war for a lead role in a cage?
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post #2 of 18 Old 03-22-2016, 12:08 AM Thread Starter
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Four Airbox Mods (cont.)

I made the following mods to my airbox and thought I'd share it with the group if anyone is interested;
  1. Snorkel Farkle
  2. Breather Baffle
  3. Catch-Can
  4. Bee Blocker

2) Breather Baffle: The second mod is to the breather sponge pocket inside the airbox. The purpose of this sponge is to condense oil vapors out of the air coming from the breather tubes attached between the airbox and the crankcase. The condensed oil is then suppose to run back down into the engine returning via front breather tube. You can see in the sponge pocket where it narrows on the right some brown streaks of oil running UP the wall and into the air intakes. I didn't like the idea of breather oil getting into my intake air so I modified the system in a couple of ways;



I took the flow straightener from an old air filter and cut it so that it fits down in the pocket and rests on the two stanchions that normally keep the breather sponge off the bottom of the pocket. I ran a bead of oil-resistant gasket seal around the perimeter of the baffle (not shown) to prevent breather gases from sneaking past it and the sponge and not condensing the oil before hitting the intakes. One problem I noticed is that Suzuki just wedges a rectangular sponge into that weirdly shaped pocket. I bought a new sponge to replace my old sponge here;



You can see how the old sponge just scrunches up in that narrow corner and allows gaps so it doesn't seal well. The oily breather vapors can bypass the sponge thus increasing oil burning. I took the time to trim my new sponge with a razor knife to fit the odd shape. I also ran a bead of sealant in the sharp corners of the narrow area and also I noticed that the breather pocket gets wider at the top so I sealed those gaps as well;



The baffle should create a better "compartment" below the sponge for the front and rear breather tubes to huff breather air back and forth and the pressure drop across those small holes should improve the condensation of oil vapor and reduce oil burning. The better fitting sponge should also improve the efficiency of the system. I included the baffle pattern is a pic attachment if anyone wants to try this.

3) Catch-Can: If you do a search for "PCV oil catch-can" you'll find a number of companies offer engineered solution to intercept the condensed breather oil before it can return to the main oil supply. The idea is that this "oil" is probably full of contaminates from combustion, acidic & etc and probably not the best thing to put back into the oil sump. These solutions are expensive and there isn't a lot of space to install one on a motorcycle but some people do. While working on the breather sponge I realized that since all the oil returns to the engine via the front cylinder breather tube it would be easy to design something to catch it before it returns to the engine. You can see my contraption in this picture here, a poor man's catch-can.



The clear plastic tube is plugged into the front breather port instead of the front cylinder breather tube and goes to a T-connector. I bought some oil resistant clear tubing and that T connector is a Suzuki part for the PAIR system on the right hand side of the airbox. So the front breather tube plugs into that T and any returning oil falls down into the long tube below. When I do the final install I will cut the tube to length to be accessible on the left side of the bike with a plug on the end. When it fills up with oil I can unplug it and drain out the bad oil that would have returned to the oil sump.

4) Bee Blocker: When I intially got access to the airbox on my project bike I was surprised to find 25-30 bee and insect carcasses in the airbox above the filter. I don't know how many miles was on the filter but it was pretty dirty. A few dead bees is probably no big deal but I think a bee smashing into the filter probably releases bee juice on the paper filter and then the juice probably attracts dust and plugs a small area of the filter. To prevent this I installed the bee blocker which is just a piece of plastic "gutter-guard" to keep leaves out of roof gutters. You can also see this in the picture above tie wrapped to the inlet snorkel. I had to buy giant roll of it so, while supplies last, if anyone wants a piece of gutter-guard PM me your address and I will mail you some.

FYI, try these mods at your own risk. Enjoy!
Attached Images
File Type: jpg Week71 002A.jpg (74.3 KB, 834 views)
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File Type: jpg Week71 007A.jpg (66.3 KB, 755 views)
File Type: jpg Week71 015A.jpg (116.0 KB, 98 views)

Pink Floyd: And did you exchange a walk-on part in the war for a lead role in a cage?
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Current: 2014 V-Strom DL650 ABS Red
Next Up: ?
Past: Suzuki: DL650AK7, GS400; Honda: CB125, Express 49cc
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post #3 of 18 Old 03-22-2016, 11:13 AM
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I added a piece of coarse metal screen to my intake after finding quite a few bees and other insects in the air box. Judging from what I got to brush off of it periodically, it's a very worthwhile mod. Thanks for sharing all your info.
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post #4 of 18 Old 03-22-2016, 11:35 AM
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Several of us have put regular window screen in front of the intake to keep the bees and big bugs out.
Finding so many dead things was a surprise when I first checked the air box. subsequent inspections showed no collections.
Since I rarely ride in the dirt I don't check it often tap out the built up dust.

I hope you can quantify the benefits of the air stream redirection and other mods with better mileage or some such.
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post #5 of 18 Old 03-22-2016, 08:26 PM Thread Starter
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Quote:
Originally Posted by notacop View Post
I hope you can quantify the benefits of the air stream redirection and other mods with better mileage or some such.
Unfortunately I have no way to quantify the benefits, if any. I don't have MPG records from the PO and I only rode it for about a month after I bought it before I shut it down for major repairs, so I don't have much butt-dyno experience for the before/after comparison. The test is confounded by other mods such as fresh cams, new air filter, cleaned injectors, etc. In the "famous last words" department, I am installing it on the premise that it "can't hurt"!

There is a local company that puts on "dyno-days" and gives free dynamometer tests a couple times a year. I might do that when I get it running just to see how my bike compares to similar models and track the MPG just to see what it is but I have no baseline. I am very interested to see how much oil is captured by the Catch-Can. I want to track that in cc's/mile or something like that and plot it over time. Hopefully someone else adds one to their bike and we get data to compare.

Pink Floyd: And did you exchange a walk-on part in the war for a lead role in a cage?
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Current: 2014 V-Strom DL650 ABS Red
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Past: Suzuki: DL650AK7, GS400; Honda: CB125, Express 49cc
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post #6 of 18 Old 03-22-2016, 09:40 PM
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I found the sponge material in my bike after I dumped it and did the air box inspection. It seemed fine. Wiped out the excess oil and upon subsequent inspection everything was fine.
It's good that you've made what seems to be improvements, DIY should never be repressed. The screen to keep out the bug bodies has to be the best improvement.
I'se just razzin you about the quantified bennys.
Reason for the Razzin is that the engineers at the factory have spent hours if not weeks designing all the parts of the bike to work together within the scope directed them to make a marketable, profitable bike foe Suzuki. .
All the earnest owners that put throttle controls, after market pipes and the like in the search of "more" usually only satisfy their sense of accomplishment.
Not that suspension mods haven't made a better ride but to those of us with dead butts, the stock is OK.
The Wee has 80+K miles and i don't find fault with the original suspension.
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post #7 of 18 Old 03-23-2016, 02:33 PM Thread Starter
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Quote:
Originally Posted by notacop View Post
It's good that you've made what seems to be improvements, DIY should never be repressed. The screen to keep out the bug bodies has to be the best improvement.
My favorite is the improvement to the breather sponge/pocket and the catch-can.

Quote:
I'se just razzin you about the quantified bennys.
Razz away notacop, I think I can handle it :-)

Quote:
Reason for the Razzin is that the engineers at the factory have spent hours if not weeks designing all the parts of the bike to work together within the scope directed them to make a marketable, profitable bike for Suzuki.
On a budget bike there are trade-offs. Suzuki could buy custom molded sponges for the breather box and improve the seal or use sealant on assembly to reduce oil consumption. But it might add $5+ to the cost of the bike but for what benefit? Most riders would never see the benefits of longer lasting spark plugs, less carbon build up in the cylinder head at EOL, etc. so they don't do it. And $5 x (number of bikes sold) is probably not an insignificant number of dollars. From what I have seen the design life of these bikes is probably only around 60K miles, anything beyond that is purely accidental gravy. The individual owners don't have these constraints.

Quote:
All the earnest owners that put throttle controls, after market pipes and the like in the search of "more" usually only satisfy their sense of accomplishment.
There is certainly value in a sense of accomplishment but I agree with the idea that if you want more power just buy the DL1000 or something else. I enjoy finding cheap, simple improvements to the design that Suzuki can't implement without turning their budget bike into a BMW. I admit that some of the benefits may only be in my mind, like the Snorkel Farkle, but it only cost me $7

Quote:
Not that suspension mods haven't made a better ride but to those of us with dead butts, the stock is OK. The Wee has 80+K miles and i don't find fault with the original suspension.
Enjoy the ride!

Pink Floyd: And did you exchange a walk-on part in the war for a lead role in a cage?
---------------------------------------------------------------------------------------------
Current: 2014 V-Strom DL650 ABS Red
Next Up: ?
Past: Suzuki: DL650AK7, GS400; Honda: CB125, Express 49cc
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post #8 of 18 Old 03-23-2016, 09:47 PM
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You are a very serious person! The only oil I found in the air box is after a fall over and GW says that is normal. So I wiped up the mess and try to not fall over no mo.
I' not sure the gluing in place is necessary but what the hey. Go for it!
I believe the carbon build up was common on low compression engines like Brit bike in the 50's. Maybe cars of that era. Tetra ethyl lead in the gas and that sort of thing.
Anyone strip an engine down and de-carbon the piston anymore?
Plugs, they last dang near forever. I swapped mine at 80K+ miles and the old ones looked good still. I only changed 'cus I had new ones under the seat.
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post #9 of 18 Old 03-26-2016, 11:44 PM Thread Starter
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Catch Can Rev 2.0

I made a mod to the mod. I inserted the T-connector into the Suzuki front cylinder breather tube and dropped the clear tubing down from there. This should still intercept oil before it returns to the crankcase and should work as before. The advantage is that if it causes problems or catches no oil, etc. then I can easily bypass it by replacing the T-connector with a straight coupler and hopefully do that without removing the airbox.

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Pink Floyd: And did you exchange a walk-on part in the war for a lead role in a cage?
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Current: 2014 V-Strom DL650 ABS Red
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Past: Suzuki: DL650AK7, GS400; Honda: CB125, Express 49cc
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post #10 of 18 Old 04-25-2016, 12:49 AM Thread Starter
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Quote:
Originally Posted by dmfdmf View Post
I made a mod to the mod. I inserted the T-connector into the Suzuki front cylinder breather tube and dropped the clear tubing down from there.
Catch Can Rev. 2.0 worked out pretty good. I got lucky, since I didn't actually measure it, but the place I cut and installed the T-connector in the front breather tube was perfect as it dropped the catch can right down the elbow of the upper radiator hose and aside the front cylinder. Here is a pic.



You can see the T-connector just above the V-bracket upper engine mount and the clear hose drops down along the front cylinder. I didn't want the tube to rest/melt against the cylinder so I installed a bolt in the hole in the front cylinder that is plugged with a black plug. I used a spare banjo bolt from the ABS block under the bottom triple clamp. It had a hole in it so I used some black wire from a piece of Romex to create a bracket and hold the clear tube away from the cylinder. At the bottom I added a clamp to the engine case bolt and plugged the hose with a banjo bolt and sealed it with a hose clamp. Here is a close up of the end plug.



You can see that so far the Catch Can is empty but after 200+ miles there is a tiny, tiny amount of trapped oil wetting about 2 of the 8 threads in the banjo bolt at the bottom (you can't see it in the pic) so I think it is working. At this rate it will be a while (I hope) before I need to drain my Catch Can. If I send that oil in for analysis I will update the thread.
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File Type: jpg Misc 007AC.jpg (85.1 KB, 563 views)

Pink Floyd: And did you exchange a walk-on part in the war for a lead role in a cage?
---------------------------------------------------------------------------------------------
Current: 2014 V-Strom DL650 ABS Red
Next Up: ?
Past: Suzuki: DL650AK7, GS400; Honda: CB125, Express 49cc
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