• 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.

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Air Box side removal? Mod?

C

carl johansson

Husqvarna
C Class
2005 450 Te. bought it from an enduro H&H racer in Georgia. I ended up having George Erl rebuild the engine because of all the clay and sand ingested into the engine. So in taking the thing apart - the airbox is "missing" it's sides. It looks like there were plastic plates enclosing the left and right side of the box at one time - but the guy pulled em off - I guess to get more air into the box, so the only thing between the dust and dirt and the foam filter and the body plastics.

Is this a common modification? If so - does it really make a difference in performance? because it clearly made a difference in destroying an engine with all the grit that got in.
 
This is normal (i.e. not a mod), at least on a 2009 TE. I'd be surprised if the 2005 model was different, in that regard.

The filter is what should've stopped that stuff from getting to your engine.
 
AndrewS;104617 said:
This is normal (i.e. not a mod), at least on a 2009 TE. I'd be surprised if the 2005 model was different, in that regard.

The filter is what should've stopped that stuff from getting to your engine.
Click to expand...
you mean it came from the factory likethat? If so - why are there holes in each of the corner where you would seem to attach the sides of the box? they look like holes from self threading screws!
 
carl johansson;104631 said:
you mean it came from the factory likethat? If so - why are there holes in each of the corner where you would seem to attach the sides of the box? they look like holes from self threading screws!
Click to expand...

Couldn't say. Have to agree with others though. You take off the side body panels on the 07 TE 450 and it's just an open airbox under there....with a really big open drain slot at the bottom.
 
The open sides are normal- it's the way the bike came from the factory.
Its the air filter & air filter oil, that's going to decide whether any crap gets into the engine or not. The air box really just protects the air filter from mud, stones and crap flying off the rear tire etc.

It's not impossible for the air filter to have been improperly installed at one point, leaving a gap on one side around the rim. If this happens, you may as well have no air filter on at all.
Also if they used the wrong type of oil, oiling practice, or no oil at all would lead to problems.
A worn air filter is also a possibility.
 
If it helps any, I've attached an illustration of the airbox from the 2005 parts manual.
 

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That is the way mine looks too. I put 1 1/2x1 1/2 foam strip by the front top of air box by the upper shock, bottom of gas tank. There is a big gap there. I filled it in with foam to block out mud and water. Works good for me. The top of air filter stays much cleaner longer.
 
If you want added insurance a filter skin helps. I use the hair nets they use in hospitals coated with Motul filter oil. if its a dusty ride I take it off at the lunch break.
 
All the older 2 strokes have a rubber flap at the top front of the airbox to prevent blast from coming in under the tank. Also the sides were on the airbox attached with small aluminum rivets-the sides have vents.
 
ghte;104795 said:
If you want added insurance a filter skin helps. I use the hair nets they use in hospitals coated with Motul filter oil. if its a dusty ride I take it off at the lunch break.
Click to expand...

Good idea on the hair nets! Never thought of that. I have plenty at work. Do you still oil them? How do they fit?
 
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