Air Filters too expensive? Try this mod for $5.95 - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 60 Old 10-31-2008, 05:41 PM Thread Starter
 
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Talking Air Filters too expensive? Try this mod for $5.95

After getting sticker shock on the cost of a new OEM or K&N air filter I started looking for alternatives. I found that with a little work, you can use your old DL1000 air filter as an "adapter" for inexpensive Chevy Cavalier air filters and others. The one I used was for a Chevy Cavalier - 4 cyl. 134 2.2L F.I. (VIN F) (2003-2005), but I basically measured the old filter's element (5.5"x6.5") and then with tape measure in hand, went down to the local auto parts store and began going through the air filter section until I found one I thought would work. Below are a few "PiCtUrEs FoR tHe TeChNiCaLY ChAlLeNgEd" which I though may be of some use...



First, you need a well lit, clean work area with plenty of workbench space.... :lol:




...and the proper tools.....



Then you need to get the old air filter out. Here I'm doing the 15K service on "Nariko" (means "Peal of Thunder" in Japanese) so she's already torn down...



The new filter is a Purolator A33590 (square one on left ) next to the V-strom's custom shaped one:



Flip the filter over. On the back, you'll see this metal mesh. You need to remove the melted plastic nubs holding it on and remove. I used a Roto Zip tool:





Next, you need to cut the old paper element out. Again I used the Roto Zip. Note I cut at an angle to get as close to the paper as possible:



Old element removed and new one ready to go in:



Next you need to enlarge the hole a bit as the new filter is slightly larger and deeper (which is good as it should breath a little easier). I marked it with a silver Sharpie pen, then took off a little at a time until the new element fit snugly.

Then clean up the hole and "score" the surface a bit for the glue to hold. I used a razor knife to smooth out the edges, then scuffed up the surface with a scotchbrite pad. You could use sand paper, but air tools make life worth living....



I used a hot melt glue gun as it holds incredibly strong, yet you can (with a bit of care) remove the new Purolator filter when it gets dirty and install a new one. I "learnt" this the hard way when I first glued the damn thing upside down. I blame the Hefe-Weizen....

Lay a good bead of HOT hot glue (some guns have variable heat settings - make sure it's turned all the way up for good adhesion on plastic and rubber). Also make sure you've got hot glue suitable for rubber/plastic as there are different kinds for different materials. Usually the "general Purpose" stuff is fine but check the package documentation. Make sure the glue has sealed all the cracks between the new element and the old filter "plate".

When you get done, it should look something like this:



Note that on my 2006 DL1000 I needed to trim a little off of the crankcase breather for the new assembly to fit:



Maybe with a little more searching I could find a more suitable, smaller replacement element which would mean not needing to trim around the breather inside the airbox. there seemed to be THOUSANDS of sizes at the Auto parts place, but the Purolator A33590 I used is both a little longer and deeper than the stock one, giving more total surface area. In this application it's pulling air in through the backside, but that doesn't matter as far as filter efficiency goes.

I hope this helps out some of you other folks on tight budgets.
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post #2 of 60 Old 10-31-2008, 06:00 PM
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I really commend you for all the research and time and effort you put into this...I really do, but with that said, if one finds that an Air Filter is too expensive(whether by principle or due to financial reasons), a motorcycle one should not have.

I'm just sayin...
BTD.
post #3 of 60 Old 10-31-2008, 06:30 PM Thread Starter
 
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Oh, I can afford it - But a penny saved is a penny earned and $25 each time for even an inexpensive air filter adds up over the life of the bike. I'd rather spend 20 minutes in the garage with the roto zip and then be able to change it for $5.
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post #4 of 60 Old 10-31-2008, 06:49 PM
 
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It never ceases to amaze me how CHEAP some Strom owners can be.:mod2_censored:
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post #5 of 60 Old 10-31-2008, 07:22 PM
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Oh come on...

...Mort.

Your tongue is going to bleed if you keep biting it like that!

Come on, big fella, let it out! You know you want to!









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L2V -- she's a stocker!...and gone...
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post #6 of 60 Old 10-31-2008, 07:41 PM
 
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Quote:
Originally Posted by henerythe8th View Post
...Mort.

Your tongue is going to bleed if you keep biting it like that!

Come on, big fella, let it out! You know you want to!
.
I damn near bit the end of it off but a promise is a promise I will do my best to be more tolerant.
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post #7 of 60 Old 10-31-2008, 07:52 PM
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You know, I'm all for saving money, which is why I do my own maintenance. I also admire you for putting in so much thinking and effort into this mod. But, I cannot endorse it. There is a point where being cheap is just being cheap. :rolleyes:

2008 DL650 a.k.a. Road Warrior, member #16 of the Flat Black Club
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post #8 of 60 Old 10-31-2008, 08:01 PM
 
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I cant think of any reason to bash the thread. sure it is a cheap fix. Is it bad? I havent heard anyone say why it is.
Next time he is going to be able to pop that filter out and glue a new one in. Sounds good to me!
Maybe all of you who oppose could elaborate why. I dont get it...

2007 DL650
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post #9 of 60 Old 10-31-2008, 08:39 PM
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Originally Posted by Guardian View Post
Oh, I can afford it - But a penny saved is a penny earned and $25 each time for even an inexpensive air filter adds up over the life of the bike. I'd rather spend 20 minutes in the garage with the roto zip and then be able to change it for $5.

I agree with your theory behind your project, that's why I bought a K&N Filter. It's a one time purchase for about the price of two Suzuki air filters. I figure in about three years I'll be "ahead" financially...even with the cost of the K&N Recharge Kit.

Sorry, but as much as it hurts me to say this, I kinda have to agree with Mortaine.

Like I said before, I do give you credit for the time it took to do your project, and the thought that went along with it...even if I don't agree with it.

BTD.
post #10 of 60 Old 10-31-2008, 08:50 PM
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I don't understand the bashing. It's not like he's changing out to a lower performing filter to save a few $$$, my thought is the $5 auto filter media is at least as good as the stuff Suzuki puts in theirs.

The only reason the Suzuki filter is so expensive is the quantity that they sell doesn't lend itself to mass production or competition for aftermarket suppliers.

On my GTS1000 they only thing available was the Yamaha part, and it needed 2; everything for that bike was unbelievably expensive. I managed to find a K&N element that would work with a little tweaking and for $30 was able to cut and glue it into shape, worked like a charm.

I used clear silicone because that stuff will hold anything.

While I'm not likely to perform this mod on my current ride since the PO installed a K&N that I'm happy with I applaud the OP for researching and documenting his steps. I'm sure it will be helpful for quite a few people, cheapskates or otherwise.

Go hang a salami I'm a lasagna hog

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