• 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 The previous version was outdated and no longer supported.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!

630 airbox mod

Based on Dinobob’s idea I’ve made what you can see here. I've used an old aluminium license plate.

Measurements under request . I hope it helps to spread the dust all over the air filter, as everyone would like it :cheers:

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I used some rubber edge trim running the full length of the airbox lid on top of the little plastic fins. My theory being it makes the fins a little fatter and running full length the fins do not push into the foam. Seems to work really well. Cheap and easy.
 
kirbybikes said:
I used some rubber edge trim running the full length of the airbox lid on top of the little plastic fins. My theory being it makes the fins a little fatter and running full length the fins do not push into the foam. Seems to work really well. Cheap and easy.
Click to expand...
I took my filter out for inspection and found some of the fins had started cutting the foam, i wasnt impressed. I had some pipe thats used for the washer jets on cars and cut it down one side and glued it on the fins like you have with the trim. It was just to stop them cutting the foam, but i found it also let more air over the filter aswell, bonus.
 
Busted RS said:
Here is my solution to the restricted / high airflow speed of the standard filter housing. At the time of installing this mod, I had already carried out the Power-Up mods, and tweaked the EFI using I-beat. I believe I noticed a small increase in performance after doing the airbox mod.
I was especially concerned the original airbox setup would drive dirt through the filter because of the very high speed airflow hitting the filter. This mod has greatly slowed the airflow hitting the filter and results in an even spread of dust accross the whole filter.
The new cover is made by vacuum forming from one of those Poly "alphabet" thermo plastics. It simply fits over the original cover, which has the 8 x 30mm holes drilled into it (later modded to 10 holes and original snorkel hole blocked) with the original snorkel removed, as the new cover incorporates the snorkel.
I beleive it could be improved a little by stricter instructions to the plastic moulder, to ensure the greatest cross sectional area of the snorkel, with less clearance allowed for the attachment screws. As can be seen, it protrudes slightly from the side if the bike, but during a number of bush rides, single track to fast fire trails, or on the road, I have never once felt it against my leg.

I'm very pleased with the end result.


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Power on regardless.
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This is by far the best solution i have seen. I dont know your riding style, but do you ride it hard?
What i wonder is sometimes you ride with legs loser and sometimes you squeeze the bike with your "knees" depending on situations... Do you feel it when holding your bike with knees? if you know what i mean :)
 
Busted RS: you went all out- nice. I'm trying a simple thing, but should improve surface exposure a bit. Binder clips (with the fold back handles removed, of course.) Just dawned on me that it's a quick way to make a broader contact patch on the foam and air flows by/through them as they're triangular. I didn't use a bunch- ended up going with about 5 spread out. And I agree- the glove in the background looks weird. :) It's my filter oil glove on a bike seat.

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Thats sorta kinda what I did except I just used a length of light aluminium 90 degree angle stock that I had laying around in the shed and just cut to length drilled and cable tied it to the pedestal bits where you have the binder clips. If ya get what I mean. will put pics up next time I take the cover off.
 
Pics as promised. I bent up a and cable tied a u piece by the intake to direct flow, then cable tied the 90degree aluminium on. I may drill some holes in both pieces for better flow and less weight one day.

The pic of the dirty air filter is after 2 dusty rides. Prior to that the only dirty part was the part by the intake, and the rest was as clean as a clean thing, so this mod definitely spreads the air around a fair bit.


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Yesterday I also cut a piece of filter to get the oil vapors coming from the engine better.
Without this cut vent pipe my be blocked by the filter sponge20170806_153457.jpg 20170806_153507.jpg
 
Interesting change they made to the airbox, the snorkel and the fins aren't there on my 610 and I think the same goes for the later models. I wonder if lowering those fins would be a good idea to improve and even the airoflow?
 
mg94 said:
Interesting change they made to the airbox, the snorkel and the fins aren't there on my 610 and I think the same goes for the later models. I wonder if lowering those fins would be a good idea to improve and even the airoflow?
Click to expand...

Hi
What do you mean by "lowering those fins"?
 
mg94 said:
I mean cutting them so that they don't hamper airflow, if they even do that. You know for power and whatnot
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If I’m understanding you correctly you may be misunderstanding the design of the box/cover (and fins.) The fins are “stand-offs”- i.e. designed to hold/push back a large surface area of the foam, so that it gets air flow over the whole surface area, from the snorkel. The problem is, though, that the fins are thin, digging too steeply/deeply into the foam and allowing it to billow around them too broadly, thus coming too close to the surface of the air of cover. That, in turn, doesn’t allow airflow throughout the box and over a large surface area of the foam.

So this is why we try wider stand-offs. It allows more air to flow. Shorter thin fins will only make the original issue worse.
 
EricV said:
If I’m understanding you correctly you may be misunderstanding the design of the box/cover (and fins.) The fins are “stand-offs”- i.e. designed to hold/push back a large surface area of the foam, so that it gets air flow over the whole surface area, from the snorkel. The problem is, though, that the fins are thin, digging too steeply/deeply into the foam and allowing it to billow around them too broadly, thus coming too close to the surface of the air of cover. That, in turn, doesn’t allow airflow throughout the box and over a large surface area of the foam.

So this is why we try wider stand-offs. It allows more air to flow. Shorter thin fins will only make the original issue worse.
Click to expand...
I see now, thank you for the explanation. So I guess this is one of the reason some folks cut holes in their airbox cover? Just asking out of curiosity, the 610 airbox design and flow is pretty different!
 
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