Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Husqvarna => Topic started by: BiG DoM on December 26, 2013, 08:13:55 pm

Title: TE 610 Airboxectomy
Post by: BiG DoM on December 26, 2013, 08:13:55 pm
Ok so the 610 airbox has always been a moot point ... in my book at any rate. Air intake is low and vulnerable to water ingress, intake is uneven into the box unless you create more vents, the seal of the outer cover is poor ... and the securing screws turn in the threaded brass inserts if you even look at them! Some of these issues were addressed with the 630 - eg raising the intake area to below seat side cover but still a weakness IMHO. Anyway I have plotted to eradicate the shyte box for some time and today when I wanted to clean the airfilter and despite all efforts to preserve the threaded inserts one bolt would not come out without turning the thread ... my mo@r also stripped  :dousing: This was the decisive moment and this is the resultant aftermath below.  >:D  

I intend to route a flexible air intake hose to the free space I now have in my battery box due to using an Ultrabatt - and fit an Uni Filter with an integrated pre-filter (dual stage 2). The pod filter will give me superior filtering and offer at least the same intake surface area, also keep the air intake away from possible water, and give the bike a nice open look I think. It will all be reversible to OEM if need be. Watch this space.  ;)


Title: Re: TE 610 Airboxectomy
Post by: adv on December 26, 2013, 08:55:02 pm
Sub


Sent from my iPad using Tapatalk HD
Title: Re: TE 610 Airboxectomy
Post by: sidetrack on December 26, 2013, 09:00:49 pm
Worst part is washing the bike the bottom part of the airfilter turns into a drooling goob because of the water mixing with the oil  :dousing:
Title: Re: TE 610 Airboxectomy
Post by: Straatkat on December 26, 2013, 10:28:14 pm
I should have done this before buying a second foam filter!
It will also make wading deep water possible, please keep us posted.
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on December 26, 2013, 10:36:19 pm
I should have done this before buying a second foam filter!
It will also make wading deep water possible, please keep us posted.

Ja I am hoping it will allow safer water crossings and also ease of servicing .
Title: Re: TE 610 Airboxectomy
Post by: Kenzogs on December 27, 2013, 08:40:04 am
I have also noticed on my TE310 that a I can gain an extra 75-80mm with a few airbox modifications. I have them planned but need to get some Q-bond to join the plastic.
Title: Re: TE 610 Airboxectomy
Post by: sidetrack on December 27, 2013, 10:51:14 am
Any progress  :biggrin:
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on December 27, 2013, 01:15:20 pm
Any progress  :biggrin:

I am now waiting for the parts but doing some other servicing and tidying up. It will be a week or two before it is complete. I am fortunate to have other scoots to go play.  :ricky:
Title: Re: TE 610 Airboxectomy
Post by: wolf skaap on December 27, 2013, 02:06:36 pm
(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=141436.0;attach=325734;image)

nice find
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on December 27, 2013, 02:14:55 pm
Lots of them on e-Bay - seem to be a standard 3" cage turbo connect. Nice part is the flex ... seen one before and is a rigid flex not like a Kreepy Krauly ... you can extend it and push it back tight again. Seems like it will do the job.
Title: Re: TE 610 Airboxectomy
Post by: sidetrack on December 27, 2013, 03:29:46 pm
Assume the Fi will automatically adjust for missing airbox and different airflow ?
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on December 27, 2013, 03:54:23 pm
Assume the Fi will automatically adjust for missing airbox and different airflow ?

Do not foresee any problem.
Title: Re: TE 610 Airboxectomy
Post by: wolf skaap on December 27, 2013, 04:34:23 pm
Assume the Fi will automatically adjust for missing airbox and different airflow ?
Yep, thats the nice thing about Fi
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on December 28, 2013, 01:51:07 am
adv and anyone else with a SM - you can pull the airbox and fit a pod filter right there to the carb. I just want mine higher and out the way. You would though need the one with a 30 degree offset to clear the frame main spar and I would go for the stage 2 filter (dual layer filter has a black inner you oil and then a red cover pre filter).

Forgot to mention that I will cap the crank case breather hose than normally exits into the air box (on the wrong side allowing oily fumes into the carb!) with a small pod breather filter as well.


 
Title: Re: TE 610 Airboxectomy
Post by: Straatkat on January 25, 2014, 10:00:22 pm
I am wondering if the air pressure in the airbox is not lower than atmosphere and as such the crankcase breather has a slight suction on it, so breathing it out to atmosphere might not evacuate the crankcase as designed..... maybe better to vent it into the 3" pipe somehow.
Just a thought.

 
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 26, 2014, 06:14:28 am
I am wondering if the air pressure in the airbox is not lower than atmosphere and as such the crankcase breather has a slight suction on it, so breathing it out to atmosphere might not evacuate the crankcase as designed..... maybe better to vent it into the 3" pipe somehow.
Just a thought.


Possibly but I am skeptical as the 610 airbox seals so badly but will have another look at it. Interestingly I am also busy with a vent mod to my G450X but this will go into a catch bottle for blow by and any oil will go back into the sump. This is to save the torque limiter 'slipper clutch' that is compromised by the hot gases having to pass through it before venting and overheats it ... thereby annealing the plates and often causing premature failure (this probably cost a Dakar podium in 2012!).
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 26, 2014, 04:07:31 pm
I am wondering if the air pressure in the airbox is not lower than atmosphere and as such the crankcase breather has a slight suction on it, so breathing it out to atmosphere might not evacuate the crankcase as designed..... maybe better to vent it into the 3" pipe somehow.
Just a thought.


Possibly but I am skeptical as the 610 airbox seals so badly but will have another look at it. Interestingly I am also busy with a vent mod to my G450X but this will go into a catch bottle for blow by and any oil will go back into the sump. This is to save the torque limiter 'slipper clutch' that is compromised by the hot gases having to pass through it before venting and overheats it ... thereby annealing the plates and often causing premature failure (this probably cost a Dakar podium in 2012!).

I see the main vent from the head goes directly into the frame and then the smaller breather from the frame to the air box ... there is then also another small engine breather at the bottom of the frame akso feeding into the frame. Makes me wonder what happens to the oil condensate from the blow by in the frame ... maybe not that much on these bikes but who knows? One would need to drill a small hole at the bottom to see if anything comes out... may just do that.
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 26, 2014, 04:17:07 pm
OK a few teasers before the bike is buttoned back up ... I noticed some lateral play in the rear shock linkages so need to pull that while I am about it. Not sure if there is any adjustment or may need to replace the bushes before I can get her together again. May also explain some weave I was getting at high speed at one stage.

So my planned airboxectomy is working out great - you will see very little of the intake pipe once the side cover is on and it really opens up the look of the bike. I will get some better pics down the line when all together - these shot quickly with the iPhone. Uni-Filter is very nice and has the prefilter cover. I will probably only need to lift the seat to service it.  :thumleft:
Title: Re: TE 610 Airboxectomy
Post by: Rough Rider on January 26, 2014, 07:28:11 pm
 :sip:
Title: Re: TE 610 Airboxectomy
Post by: sidetrack on January 26, 2014, 07:42:39 pm
OK a few teasers before the bike is buttoned back up ... I noticed some lateral play in the rear shock linkages so need to pull that while I am about it. Not sure if there is any adjustment or may need to replace the bushes before I can get her together again. May also explain some weave I was getting at high speed at one stage.

So my planned airboxectomy is working out great - you will see very little of the intake pipe once the side cover is on and it really opens up the look of the bike. I will get some better pics down the line when all together - these shot quickly with the iPhone. Uni-Filter is very nice and has the prefilter cover. I will probably only need to lift the seat to service it.  :thumleft:
Wow those Ultrabats must be small, where is it ? Is that a fuel injection setup unit below the seat ? Mod looks good  :thumleft:
Title: Re: TE 610 Airboxectomy
Post by: HK on January 26, 2014, 09:17:47 pm
Looks good , 👍
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 26, 2014, 09:23:50 pm
Wow those Ultrabats must be small, where is it ? Is that a fuel injection setup unit below the seat ? Mod looks good  :thumleft:
[/quote]

Sorry the Ultrabatt was out at the time I took the pic but fits perfectly with space for the Uni. I will take a pic with it in place - was using an U400 but now two of the new MultiMighty's - takes up about half the space of the OEM. Ja what you see is a JT Power Commander.
Title: Re: TE 610 Airboxectomy
Post by: alanB on January 27, 2014, 07:29:45 am
Hi Dom

I was skeptical when I first heard about this, but its turning out better than I thought it would  :thumleft:

A couple of questions:

1)  Have you had a chance to ride the bike yet?  Did the change in intake manifold volumes affect the bike's performance (torque curve etc?)
2) Will that pipe collapse under suction - especially where it curves around the frame?
3) How durable is the pipe in terms of developing cracks or tearing etc

Lastly, what are you doing with the old parts?  If you dont need them I would maybe be interested in them because I have some ideas about modifying the original airbox, it would be nice to experiment on a spare.
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 27, 2014, 07:47:20 am
Hi Dom

I was skeptical when I first heard about this, but its turning out better than I thought it would  :thumleft:

A couple of questions:

1)  Have you had a chance to ride the bike yet?  Did the change in intake manifold volumes affect the bike's performance (torque curve etc?)
2) Will that pipe collapse under suction - especially where it curves around the frame?
3) How durable is the pipe in terms of developing cracks or tearing etc

Lastly, what are you doing with the old parts?  If you dont need them I would maybe be interested in them because I have some ideas about modifying the original airbox, it would be nice to experiment on a spare.


Hi Allen

I have not ridden the bike yet - front end been off to do the steering head bearings and I now see some play in the rear linkages  (strangely you do not notice it when the bike is on a stand and the shock is extended as it applies force to the struts but when you start lowering it and it takes up some weight there is quite some lateral play on the dog bones/wishbone ... need to drop them an see what gives ... hopefully can be serviced and play taken up). Bike starts and runs great with no apparent difference. I have kept the old airbox in case I want to return it to standard but also sacrificed one part - I used the rubber flange cut from the intake to air box and in so doing have kept the standard intake diameter and good seal and the flare out matches the 3" tubing almost exactly. The tubing is tough - it is designed for use on turbo car engines and has integrated wire coil reinforcing running the length. It is neat stuff which I first saw at a car spares and custom place - it concertinas and bends and keeps its shape but can returned to its compressed state just by pushing it back. Definitely will not collapse on itself and I cannot see it holing easily.

At one stage I had thought of making a mould and modding the airbox so there is intake up near the top like the 630 but just seemed like such a mission for a generally flawed unit anyway. I am sure it could be done though.

Anyway will report when all together and have taken it out some.  :thumleft:
Title: Re: TE 610 Airboxectomy
Post by: sidetrack on January 27, 2014, 09:26:42 am
Wow those Ultrabats must be small, where is it ? Is that a fuel injection setup unit below the seat ? Mod looks good  :thumleft:

Sorry the Ultrabatt was out at the time I took the pic but fits perfectly with space for the Uni. I will take a pic with it in place - was using an U400 but now two of the new MultiMighty's - takes up about half the space of the OEM. Ja what you see is a JT Power Commander.
[/quote]
Slightly off topic, can you set the power curve with the commander and how is this related to the PU kit ?
Title: Re: TE 610 Airboxectomy
Post by: Rough Rider on January 27, 2014, 09:33:27 am
Wow those Ultrabats must be small, where is it ? Is that a fuel injection setup unit below the seat ? Mod looks good  :thumleft:

Sorry the Ultrabatt was out at the time I took the pic but fits perfectly with space for the Uni. I will take a pic with it in place - was using an U400 but now two of the new MultiMighty's - takes up about half the space of the OEM. Ja what you see is a JT Power Commander.
Slightly off topic, can you set the power curve with the commander and how is this related to the PU kit ?
[/quote]

I also have one fitted and it transformed the bike (it is like a jet kit for an EFI bike) it is not related to the PU kit which works by removing the lambda sensor from the exhaust.

From JD Jetting site.

"Dyno and field tested, the Power Surge 6X will allow correction for humidity, temperature, air pressure, along with race fuels and motor modifications. The tuner adjusts in a matter of seconds in 6 zones, including an accelerator pump feature for more throttle snap response. The tuner can add or subtract fuel from the injection system. Conditions like rich or lean running, and stalling from flame-out at low revs can be corrected. The Power Surge 6X stays mounted on the motorcycle or quad and is easy to understand and adjust.

The Power Surge 6X is a next generation performance tuning product for modern EFI systems. JDJetting's testing and research will provide the performance you need.

JDJetting Power Surge 6X fuel injection tuner:
-Increase power
-Improve throttle response
-6 levels of fuel injection tuning
-Adjustable accelerator pump surge circuit
-Easy to adjust at the track or off road
-Tuning logic similar to a carburetor
-Installs in minutes
-Recommended settings included"
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 27, 2014, 10:41:03 am
As said - the PU just allows the 610 to be normal rather than strangled and suffocated (puts it in open loop). The JD Tuner is a great piece of kit. Managed to pick mine up basically unused taken off a 511. JD confirmed it was same unit and the basic settings. There is at least one thread on CH regarding various settings but basically once tuned in you leave it alone. JD have a long history state side for being tuning boffins and their jets are legendary.  :3some:
Title: Re: TE 610 Airboxectomy
Post by: Rough Rider on January 27, 2014, 11:16:48 am
As said - the PU just allows the 610 to be normal rather than strangled and suffocated (puts it in open loop). The JD Tuner is a great piece of kit. Managed to pick mine up basically unused taken off a 511. JD confirmed it was same unit and the basic settings. There is at least one thread on CH regarding various settings but basically once tuned in you leave it alone. JD have a long history state side for being tuning boffins and their jets are legendary.  :3some:

I have one of their Jet kits in my RM and it transformed the bike; one of the best RM's around, it skriks for niks  :ricky:
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 27, 2014, 11:49:06 am
As some of you may have realised I am a addicted farkleologist and cannot leave anything standard.  >:D  Just as well I am not into Harleys  :patch:
Title: Re: TE 610 Airboxectomy
Post by: sidetrack on January 27, 2014, 02:12:00 pm
HK has the PU kit on his 2009 but still wants more oomph, the PC may be the way to go ?
Title: Re: TE 610 Airboxectomy
Post by: BiG DoM on January 27, 2014, 02:39:11 pm
HK has the PU kit on his 2009 but still wants more oomph, the PC may be the way to go ?

A freeflow exhaust and more free flowing air box coupled with the PC is the way to go. These scoots though do make their power low down and linear - that is their beauty (it is not a 690  ::))