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Discussion Starter #1
I just received my kit on Friday. Mighty fast i might add. I installed it and have taken two test runs. Here are my initial impressions. Keep in mind i have not yet installed my EJK or my Vance and Hines slip-ons.

1. The performance boost is substantial. I live at 7000 feet and the bike felt very sluggish. Now at ALL speeds i have excellent acceleration. She really need some air.

2. I haven't ran a full tank yet but the gas millage seems to have improved from 35 MPG to 45 MPG and i am an AGRESSIVE rider.

3. The bike is running much cooler.

I almost can't imagine why i would need the Dobek at this point but it's on order.

I was also wondering, Joe, why we keep the stock air filter on the left….?
 

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The answer to the last question is looks. At least for me, the gaping hole left without the cover is ugly.
 

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My apologies.
 

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Only real reason to keep that filter might be to dampen the noise that might crossover. I'm still considering how I can go about converting that space into storage.
 

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Chucksters

Looking to purchase a Chucksters Big Air Kit. How do you get a hold of this company? I sent an email and received no response. The website has no other contact info other than email. Anyone have a phone number?
 

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SFMoto got a pic or two? Been interested in that kit for my Voyager, and I DO NOT want anything I need to get a fuel controller.

about converting that space into storage.
Only if you want to bake cookies...... in less than a minute
 

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SFMoto got a pic or two? Been interested in that kit for my Voyager, and I DO NOT want anything I need to get a fuel controller.

Only if you want to bake cookies...... in less than a minute
Hey Bubba,

from the outside it looks bone stock. But the backside of the air box is gone. I didn't take any pics but if you want me to take it apart i can. I like Chucksters because it gives the performance of all the others but leaves the stock air box. I was afraid others would stick out too far.
 

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Looking to purchase a Chucksters Big Air Kit. How do you get a hold of this company? I sent an email and received no response. The website has no other contact info other than email. Anyone have a phone number?
I used the contact form on their page. Joe has always called me back the same day and has been very responsive.
 

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Discussion Starter #11
So with this air kit you don't need a fuel controller? Even if you have changed the pipes?

Well. I initially ran without it and it seemed to run fine. Joe did too for a while. But I did buy and install it just to be safe......
 

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Well. I initially ran without it and it seemed to run fine. Joe did too for a while. But I did buy and install it just to be safe......
By any chance, did you check the plugs when running the kit without a fuel processor? I also wonder if a resistor inline with the air temp sensor would work?
 

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Discussion Starter #14
By any chance, did you check the plugs when running the kit without a fuel processor? I also wonder if a resistor inline with the air temp sensor would work?
No i did not. It was only a week. The bike seemed to run great without the ECM
 

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Joe called me back and was extremely helpful. Thanks for the feedback. The only problem I have with power is when I ride two up, so I told my girlfriend to stay home. She didn't like that idea, so I am getting a big air kit for my Birthday present at the end of the month! Just kidding about my girlfriend staying home, I love my sweetie! I have a question, I want to keep the stock pipes, so I plan to drill out the baffles to increase air flow. Do I need a special drill bit or an extension to reach through the pipes? How large of a drill bit do I use? How many baffles in each pipe? Do I need to take off the pipes to do this project?
 

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:serious:1
Joe called me back and was extremely helpful. Thanks for the feedback. The only problem I have with power is when I ride two up, so I told my girlfriend to stay home. She didn't like that idea, so I am getting a big air kit for my Birthday present at the end of the month! Just kidding about my girlfriend staying home, I love my sweetie! I have a question, I want to keep the stock pipes, so I plan to drill out the baffles to increase air flow. Do I need a special drill bit or an extension to reach through the pipes? How large of a drill bit do I use? How many baffles in each pipe? Do I need to take off the pipes to do this project?
You need a 1 3/4 inch bi metal hole saw and a short extension. Baffles will come right out. No need to remove the mufflers.
 

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I just saw the film clip on the new Gadget site, so I now know what a baffle looks like. The baffle was removed from a 1500 Nomad using the 1 3/4 bit. I have a 2005 1600 classic, which has different pipes with a wider mouth. The opening of the baffle is surrounded by approximately 1/2" of metal. Do I need to just drill around the opening of the baffle to get it out or will that metal trim get in the way of removal?

BTW, I am glad to see that site up and running again. Very helpful tips!
 

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I just saw the film clip on the new Gadget site, so I now know what a baffle looks like. The baffle was removed from a 1500 Nomad using the 1 3/4 bit. I have a 2005 1600 classic, which has different pipes with a wider mouth. The opening of the baffle is surrounded by approximately 1/2" of metal. Do I need to just drill around the opening of the baffle to get it out or will that metal trim get in the way of removal?

BTW, I am glad to see that site up and running again. Very helpful tips!
Removing the actual baffle is not required and is a messy job, that only one or two 1700 owners have done with limited success. The 1700 baffles are unique and nothing like those of the 1500 or 1600 so forget any tutorials concerning those models.

All you need to do is drill thru the two plates in the central core of each baffle using a 1-1/4" Diameter Bimetal Hole Saw (Not 1-3/4"). You will need an extension or two to reach the plates since the first plate is about 6" from the end (outlet) and the second plate is at least another 6" further in. Be careful with the 2nd plate as the catalytic material is just behind it. You may need to fish out the slugs you cut out with a magnet if you don't have a good hole saw that retains the slug.

Try drilling out just the first plate in each muffler first to see if you like it. You cannot go back once you drill out the second plate and you are much more likely to get decel popping with both plates removed.
 

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Thanks guys for your feedback. The baffle that was removed in the film clip looked like a tube, so I do not see how that tube can restrict air flow by that much to make a significant difference in power. I am going take this mod one step at a time. I will start with the air kit and go from there.

Joe from Chucksters Customs said I will see a boost in power with the kit. If I am looking for more power he suggested adding new pipes and a fuel management system. I love the look of the stock pipes so that’s not an option. I will take your advice Vulcan Hammer and just drill out the first plate. From what I read on this forum, I guess I do not need a fuel management system since I am keeping the stock pipes.

Thanks again and I will keep you guys updated.
 

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Would one of you guys that bought from joe give a step by step install process for the rest of us thinking about it, for the 1700's....thanks....ride on....
 
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