I made the following mods to my airbox and thought I'd share it with the group if anyone is interested;
2) Breather Baffle:
- Snorkel Farkle
- Breather Baffle
- Bee Blocker
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.
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!