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 The previous version was outdated and no longer supported.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

sms630 Airbox and PU Kit

Wacko9

Wacko9

Husqvarna
Hi people

I have an sms 630 here in England, UK and have been searching the forums finding out about the power up kit and adjusting the filter i.e. removing the funnell and a maze behind the filter which im pretty sure doesnt exist on mine.
What i want to know is actually HOW to do the power up kit yourself? I know about the 3 components i need but dont know how or where to fit them.
Also with the airbox, what and where is this maze and what other modifications to the airbox have people done?
I am also looking for a pair of slip on cans that arn't £1,000 and where to get them?

Any thoughts please reply, cheers
 
The pu kit is two things.​
​
A plug for the O2 sensor on the exhaust. And the chase the wire that comes with the factory O2 sensor disconnect that and plug the other cap with a resistor that comes as part of the pu kit.​
​
The plug part should be around the left side of the fuel tank towards the middle. It is tucked in around the center support frame but on the left side. It can be done without taking the tank off if you have small hands. Just loosen up the tank and lift it up a bit.​
 
Forgot to add, also people get rid of the vapor can on the right side of the engine. Just plug off the hoses at their source.
 
I just did this to my new 2011 sms630 so it is fresh in my memory.
The complete power up is 4 steps. Luckily is can all be done for nearly free.
1. Remove the carbon canister (no power gain just looks and weight savings)
2. Power up plug. Use a resistor to fool the ECU into giving more fuel to the engine. (big power increase)
3. Get more air to the engine. Remove the plastic labyrinth plate and drill some extra holes in the airbox cover. (big power increase)
4. Get more exhaust out of the engine. Remove the catalytic convertors from the exhaust pipes to make them flow better.

You need to do at least the first three. Here is what I did:
1. Unbolt the carbon can. Leave the line attached to the tank with the check valve in it. That is the tank vent and can't be plugged. Remove everything else. Use a rubber vacuum cap to plug the vacuum line connector at the intake (where you removed a line to the carbon can).
2. This is the Best mod. Leave the O2 sensor in place so no plug is needed (and it looks untampered with). Disconnect the grey o2 sensor connector, cut the grey connector off the end of the o2 sensor cable, leaving 2" of wire left attached to the connector. Solder a 2.2K ohm 1/2W resistor across the two white wires (to the ECU), tape or heat shink to protect the resistor. Connect the grey connector back onto the wiring harness. If this is done properly the engine will display no codes (on the neutral light) and the engine RPM will jump to about 2000 (from stock 1650). This work can be done with the gas tank shifted aside but not completely removed (fuel line still connected). note: my first attempt at this with the resistor plugged into the ECU end of the connector didn't work for me and I got codes and no power. Using the connector is foolproof (I have done four so far). Adjust idle back to 1650.
3. Remove the air filter (wash and reoil it with decent oil) and remove the plastic labyrinth plate behind it. Remove the snorkel from the airbox cover. Drill 3ea 1" holes in the airbox cover next to the snorkel hole. I could easily fit 3 holes than are all hidden by the side panel. Others have put more holes in. My rule of thumb is 4X the area of the TB opening (40mm). There are lots of pics on the site.
4. I haven't done this yet but there are lots of how to posts on here. There are 2 stages. You can cut it appart and just knock out the cat section, or some have removed the entire inner section, welded in a perforated tube, and turned it into a glasspack muffler like a 2-stoke dirt bike uses. The last option is more work but yields a bit more power, nicer sound and save a fair bit of weight. That is the one I will do soon. Some where using a 2" perforated tube but I was checking my CBR900RR fireblade's Yoshi can and it only uses a 1.25" tube. I will go with 1.5".

The result is that my bike has a super smooth idle with no lean surging.

Hope this helps someone. Cam.
 
Wacko9 said:
Hi people

I have an sms 630 here in England, UK and have been searching the forums finding out about the power up kit and adjusting the filter i.e. removing the funnell and a maze behind the filter which im pretty sure doesnt exist on mine.
What i want to know is actually HOW to do the power up kit yourself? I know about the 3 components i need but dont know how or where to fit them.
Also with the airbox, what and where is this maze and what other modifications to the airbox have people done?
I am also looking for a pair of slip on cans that arn't £1,000 and where to get them?

Any thoughts please reply, cheers
Click to expand...
Wacko buddy where in the Uk are you.I have fitted PU kit,and Arrows cans with ECU from Adrenlin Husky.My next step is to find out little more about air box mods as me to a bit unsure,perhaps someone might post some photos,and then fit a JD Tuner.Im Lincolnshire buddy.
 
Fitting instructions come with the JD. And (on e-mail request) he´ll send you a ton of photos. It looks complex but is very easy to install.

http://www.jdjetting.com/xcart/product.php?productid=122&cat=8&page=1

Don´t think Euro 630s have got the carbon canister.

And think the hedgehog tabs in the airbox are mainly intended to separate the filter foam from the surface of the box and thereby increase air flow. (The maze is mainly to be found on U.S. 630s)

http://wwm.ehsracing.com/store/Items.aspx?code=ABX-UNIV&key=cat

... is a good place for a watertight air box vent cover. May not look the dogs ... but it works.
 
Thats a massive help Cam, cheers for that. So all you are really doing is disconnecting the o2 sensor and sticking a resistor on the end?

Removing the cats from the exhaust sounds like the least messy and should get a good power gain.

Another decision between the JD tuner and power commander.

Also has anyone got any suggestions with just slip on cans for UK?
 
Wacko9 said:
Thats a massive help Cam, cheers for that. So all you are really doing is disconnecting the o2 sensor and sticking a resistor on the end?

Removing the cats from the exhaust sounds like the least messy and should get a good power gain.

Another decision between the JD tuner and power commander.

Also has anyone got any suggestions with just slip on cans for UK?
Click to expand...
Speak to Nathan at Adrenalin,Husky dealer in Warrickshire.I bought the Arrow pipes direct from them,comes with PU Kit,ECU and spark arrestors.I am now looking at getting a JD Tuner and air box mods
 
My riding partner was able to knock out the cats without taking the pipes apart. He used a carpenters chisel from the inlet end and some patience. He claims better sound and a slight but noticeable power increase. I sill like the idea of making a glass pack. Cam.
 
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