Kawasaki Vulcan Forum banner
Cancel

V2k Stock air box modification

4768 Views 9 Replies 4 Participants Last post by  RuaphuNZ, 
V
I've been messing around with the air box lately trying to open it up a bit to let it breathe more easily, so i thought I'd share some pics of the result in here.
I initially just cut away the entire bottom and back walk facing the block and the cylinders, but then realized that it would suck in hot air from the cooling fins. At that point i really thought I had screwed it up, but realized that if could find a black plastic jerrycan, i could but out and glue in a new back plate, and use some of the curved areas, like the handle on it, to make some nice radii inside and along edges of whatever i made. So a new back wall was made with a big radius at the top going inward. Having the entire bottom cut out, where those rubber inlets were, i made some roundings on the forward and backward facing edges to let the air curve nicely up into the box. Or at least that's the theory. I extended the back wall downward as far as possible to prevent as much hot air as possible from entering from the cylinder fins.
So here is the result. It may not be pretty, but i think it'll work pretty good. I got a K&N filter to go on there too along with V&H Powershots and a PC3.
Let me know what you think.

Attachments

See less See more
5
Reply
Save
Like
1 - 10 of 10 Posts
Poncho Villa
open her up

VN2kDane said:
I've been messing around with the air box lately trying to open it up a bit to let it breathe more easily, Let me know what you think.
Click to expand...
dane, why mess with the all the restriction of a stok air box? be rid of that whole confabulation and make your own Free Breather.
1/8" alum plate is $10. k&n air filter $25. hardley airbell cover. $50. half duzen :beers: $6. this bad boy is gonna set you bak a full Cnote b4 shes dun.
while yor in ther, take them secondary butterfly valves off their stems, they jus slow you down. poncho

Attachments

See less See more
4
Reply
Save
Like
V
Poncho, while that looks like a nice filter in those pics, I'd rather go with something that resembles a stock airbox. Cops in Denmark are really anal about customized bikes, let alone cruizers. We're hardly allowed any custom parts without that e-mark (some European test approval thing) for bikes produced since 2004, and especially power enhancements are restricted. I allready have Powershots on, so I draw enough attention as it is. Besides, an open filter gets wet in the rain and all that.. and I like the look of the stock cover.
Regarding the secondary butterflies, I already removed them. It's stille cold here, so it has some issues running smooth without them. Hope that changes in a month's time, when my ensurance allows me to ride again.
Pricewise, that modification hasn't cost me more than about $10 for the jerrycan and same for some epoxy glue. I bought the filter a while back, so I don't count that in here.. :D I'm happy. :cool:
See less See more
Reply
Save
Like
Poncho Villa
VN2kDane said:
Cops in Denmark are really anal about customized bikes, let alone cruizers. We're hardly allowed any custom parts without that e-mark (some European test approval thing) for bikes produced since 2004, and especially power enhancements are restricted.
Click to expand...
this side of the pond, we dont appreciate the FREEdom we still have (whats left of it) while the leftwing libs here try to make this place resemble your neck of woods. if they like it so much, they should just move there and leave this place as it is. then we can clean up the mess they'v already made.
it wont be long before we are being told (law) when to get up and when to sit down. they already tell you when to shut up. PC police. you cant speak the truth because somebody mite get their feelings hurt.. oh, thats right we have that here too..

but yor airbox, you fixed it. how is it different than b4 you cut it up?
Reply
Save
Like
RedDogDarren
Poncho Villa said:
but yor airbox, you fixed it. how is it different than b4 you cut it up?
Click to expand...
It probably has more turbulence going into the throat now. :cool:
Reply
Save
Like
V
Ponco, I haven't tried it yet, but I will keep You posted when that time comes. Like I said, I can't ride before march 1st because of my ensurance policies.

RedDog, with this mod I at lest quadrupled the intake throat area, so at least it will have enough air going into the box now. And even if some turbulence should occur (i doubt you can avoid it entirely), I doubt it will have any negative effect with the increased availability of air.

I will get it dyno'ed within two months time to adjust the PC3, so I'll see the result then.
Reply
Save
Like
Poncho Villa
RedDogDarren said:
It probably has more turbulence going into the throat now. :cool:
Click to expand...
rdd, airflow after the filter is still routed thru those elephant trunk snorkels. They should remain somewhat laminar.?

this mod opened only the bottom of the outer airbox, I don't see much change from stok. But the motor will only suk as many CFM as displacement - rpm - exhaust restriction/relief will allow, not more... Unless you positive pressurize the intake manifold, super or turbo charged. poncho
Reply
Save
Like
RedDogDarren
I was mostly kidding about the turbulence aspect. It's just that there are so many variables in the science of air intake your immediate goal must be that there is no power or driveability loss. If you have a gain that is a huge accomplishment when you alter your airbox.
I spent over a month doctoring my old TLS airbox. It was smoothing, adding volume and truly sealing the box with layers of plastic and epoxy to create a stronger pressurization threshold. I also did a LOT Of testing with the intake tubes and super sealed those as well.
It's a fun process but easy to make worse.
Reply
Save
Like
V
Well, the stock intake throats are gone along with whatever restrictions the caused. I believe they caused some, because they were designed for the stock filter. The K&N filter handles around 150% the CFM that the stock one did, so in that sense something needed to be done. And the engine only sucks as manu CFM as it can get through the box. Restrictions, no matter the magnitude, causes more vacuum before the trunks and hence less air into the engine, and a stock filter box is indeed a restriction, a lot more that this has become. :)
Reply
Save
Like
RuaphuNZ
Dane, I done the same with my set up a while back, K& N cos the paper filters are stupidly priced down here, removed secondary butterflies but left shaft in, removed snorkel bits off intake and removed the rubber intake bits on the outer part of airbox. Had a good result over all, bike burns cleaner, improved roll on and slightly improved mph. So no grumbles with the set up. Ando
Reply
Save
Like
1 - 10 of 10 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Kawasaki Vulcan Forum
A forum community dedicated to Kawasaki Vulcan motorcycle owners and enthusiasts. Come join the discussion about performance, modifications, Vulcan 1500, Vulcan 2000, Vulcan 500, Vulcan 1600, Vulcan 900 and all other Vulcan motorcycles.
Full Forum Listing
Explore Our Forums
Vulcan 900 Vulcan 1700 New Member Introductions General Vulcan Talk Vulcan 1500
Top