• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Step by Step air box and air filter modification

drzcharlie

drzcharlie

Husqvarna
Pro Class
So, as others have found out the air filtration system on this bike is poorly engineered. Others have led the way with the mod so I decided to do it. I highly recommend doing this. As my "How to" will show, YOU will find dirt in the air box. Credit for being pioneers to Nyjoytheride, Magoo, Quirky and Baddrapp. Thanks for the work and encouragement. "How to" write up here:

http://www.advrider.com/forums/showpost.php?p=23687271&postcount=3347

Credit to Quirky for the Parts list. You will find the list on ADV here:

http://www.advrider.com/forums/showpost.php?p=23630885&postcount=3247
 
Thanks for clearly illustrating! Can you tell me if the airbox in its original state was found to have other leaks or is the problem area confined to the OE air filter fitment?

Has anyone tried nixing the OE plastic filter holder on the door & affixing the OE filter in place by other means? I'm just going off of memory so maybe that was too much of a pita to make happen? :excuseme::cheers:
 
How come the author did not just run the neck and pod filter without the airbox labyrinth?

It would make it relatively easy to remove to clean often right? Is there another reason?
 
run-it said:
Thanks for clearly illustrating! Can you tell me if the airbox in its original state was found to have other leaks or is the problem area confined to the OE air filter fitment? Yes, there was air infiltration from several areas mainly near screws from the top of the air box. The biggest culprit was the OEM filter arrangement. Lots of dirt infiltration there.

Has anyone tried nixing the OE plastic filter holder on the door & affixing the OE filter in place by other means? I'm just going off of memory so maybe that was too much of a pita to make happen? :excuseme:

My opinion is that this method will NOT seal the air box adequately because the two halfs of the air box only seal with a tongue and groove arrangement without benefit of any sort of gasket. You can wait for a recall, but I think your engine will shell before that comes.



Ask Njoytheride, his did.
Click to expand...
 
huskylove said:
How come the author did not just run the neck and pod filter without the airbox labyrinth?

It would make it relatively easy to remove to clean often right? Is there another reason?
Click to expand...
I'm the author and there isn't enough vertical clearance to get a filter with the correct CFM intake because of space restrictions.
 
run-it said:
Thanks for clearly illustrating! Can you tell me if the airbox in its original state was found to have other leaks or is the problem area confined to the OE air filter fitment?

Has anyone tried nixing the OE plastic filter holder on the door & affixing the OE filter in place by other means? I'm just going off of memory so maybe that was too much of a pita to make happen? :excuseme::cheers:
Click to expand...

Originally I was going to modify the inlet. Once I got my airbox apart found that there were more problems internally with design and fitment that allowed dirt get through, even if you could seal that stupid filter assembly.

It was a nice thought, but ended up with the pod mod.

DSC07958.JPG
 
I still think the UNI pod mod can be done without removal of the airbox. Wish somebody would try. :cry:
 
Truthfully, you could do it with a hot knife. I just wasn't sure exactly where I was going to cut. From my pictures and those of Njoytherides you can see exactly where you would need to cut. The thing is that I do my own maintenance, all of it. Eventually I will have to adjust the valves and doing this mod allowed me to not only finally take care of the filter issue but it also gave me a lot of insight as to what I will need to remove to get to the head and do the valves. Yes, it was a lot of work. But hey, it was cold outside, I had nothing else to do so I did it the long way.
 
mag00 said:
Originally I was going to modify the inlet. Once I got my airbox apart found that there were more problems internally with design and fitment that allowed dirt get through, even if you could seal that stupid filter assembly.

It was a nice thought, but ended up with the pod mod.

View attachment 38798
Click to expand...

is this pic what you are calling the "pod mod", or is it 90* elbow with filter attached?
 
drzcharlie said:
Truthfully, you could do it with a hot knife. I just wasn't sure exactly where I was going to cut. From my pictures and those of Njoytherides you can see exactly where you would need to cut.
Click to expand...

What is the purpose of cutting the air box lid?
 
huskylove said:
How come the author did not just run the neck and pod filter without the airbox labyrinth?

It would make it relatively easy to remove to clean often right? Is there another reason?
Click to expand...

I think the air box is retained b/c it's needed to attach body bits. :)
 
That's correct Run-it. The side plastics, fascia and Faux tank fascia all attach to the upper and lower air box halves. Clete the "Pod Mod" is this:

i-bCPLMnr-XL.jpg


The purpose of cutting the air box lid is to allow access to the filter without gutting the bike again. With the lid cut you remove the screws from the left side plastics (the top ones) and two screws out of the cut air box lid and you can access the hose clamp on the silicone 90 at the throttle body. Pretty easy really. If you wanted you could use Gorilla tape to tape the cut back up but it would serve no useful purpose except to add a step when cleaning the filter. With the Pod in place you have a direct connection to the throttle body to the air filter. Voila' no dirt in the TB anymore.
 
I see, thanks Charlie. Probably don't have to remove the front piece that the stock filter door fastens to either then.
 
Hmmm, that is a good question Clete. I think I had to remove it to get the two halves apart. I will look when I go out to the shop.

Edit: there are at least two screws that must come out. I think the main reason is that it made the top half of the air box easier to remove since I didn't remove my fuel hose from the fuel pump. If that bit is done you may be able to remove the top half easy without removing the fascia.
 
Clete said:
is this pic what you are calling the "pod mod", or is it 90* elbow with filter attached?
Click to expand...

No, the pick with the pleated filter is what I was going to do. The pod mod is using the UNI pod filter and 90º elbow.
 
hmmmm, I've done 3400k's through a lot of dust and I have often wondered about air filter system....so this freaks me. I just pulled out the air filter (prick of a thing) and the holder seal had broken where they had glued it together. It does appear to have a poor seal around the holder and also the filter itself. Suffice to say, I will stripping her down to see how much dust is inside the air box....fingers crossed there's none.

Can we have a show of hands from those who have checked their air boxes and what they found, to gauge the extent of this problem please?
 
I have just removed the stock filter and found a significant amount of dirt behind it. Parts for this project are on order and I plan to do the job in the near future. I sure wish it wasn't such a big job but I plan to have this bike for a long time so it's important to get this done. Thanks DRZ Charlie for your work on this.
 
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