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Author Topic: TE 610 Airboxectomy  (Read 2699 times)

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Offline BiG DoM

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TE 610 Airboxectomy
« 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.  ;)


« Last Edit: December 28, 2013, 10:26:46 pm by BiG DoM »
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Offline adv

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Re: TE 610 Airboxectomy
« Reply #1 on: December 26, 2013, 08:55:02 pm »
Sub


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Offline sidetrack

Re: TE 610 Airboxectomy
« Reply #2 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:
Little by little, one travels far

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Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline Straatkat

Re: TE 610 Airboxectomy
« Reply #3 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.
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Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #4 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 .
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline Kenzogs

Re: TE 610 Airboxectomy
« Reply #5 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.
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Offline sidetrack

Re: TE 610 Airboxectomy
« Reply #6 on: December 27, 2013, 10:51:14 am »
Any progress  :biggrin:
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #7 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:
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline wolf skaap

Re: TE 610 Airboxectomy
« Reply #8 on: December 27, 2013, 02:06:36 pm »


nice find
Let the good times roll!
 

Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #9 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.
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline sidetrack

Re: TE 610 Airboxectomy
« Reply #10 on: December 27, 2013, 03:29:46 pm »
Assume the Fi will automatically adjust for missing airbox and different airflow ?
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #11 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.
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

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Offline wolf skaap

Re: TE 610 Airboxectomy
« Reply #12 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
Let the good times roll!
 

Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #13 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.


 
« Last Edit: December 28, 2013, 08:53:03 am by BiG DoM »
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline Straatkat

Re: TE 610 Airboxectomy
« Reply #14 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.

 
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Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #15 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!).
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #16 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.
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline BiG DoM

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Re: TE 610 Airboxectomy
« Reply #17 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:
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline Rough Rider

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Re: TE 610 Airboxectomy
« Reply #18 on: January 26, 2014, 07:28:11 pm »
 :sip:
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Offline sidetrack

Re: TE 610 Airboxectomy
« Reply #19 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:
« Last Edit: January 26, 2014, 07:45:41 pm by sidetrack »
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north