Constrictor's Caddman Air Mod Tutorial (56k Warning)

[Spok]

Originally Posted by KawiKen

Spock Said -
remove the rigth side cover, replace with caddmann covers, remove the left side,block off corssover tube, or not, put caddmann covers back on...thats it

Spok, Did you rejet at all? I know you have aftermarket pipes, just curious if you rejetted when you re-piped or did the Caddmann? If the vulcans run lean from the factory, isn't cramming more air into them going to make them even leaner?

Thanks for your input!

I had rejetted long ago, way before the caddmann mad. I still need to adjust my air/fuel mixture, too lazy to go pull it apart right now. I think I'm running ok, maybe just a tad lean, will take a look at my plugs too, I had just changed them out right prior to the mod.

[Treym]

Just finished this wonderful mod on 03 MS. It was the best $100(2 Mr Gasket
aircleaners and 2 K&N filters from Summit) and the easiest hour I have spent in a long time. I took for a quick spin aroung the block and this is awesome.
It not only looks better, runs better and the sound is killer. More air in means more air out.

[joecruiser]

I tried it but didn't like it. I didn't like the way it sounded. Didn't really feel the increased performance many write about. Maybe because I still have the stock exhaust. I had the pods set at a conservative g2:15, y2:30, r Off. My milage took a nose dive. My Low fuel light came on at 122 miles when before I could go 170 miles. I've put everthing back and turn off all pods on TFI. The bike runs really rough now. I have no clue why. I must have done something wrong.

[Constrictor]

Thunder advertises a 10 RWHP increase on a 1600 Mean Streak on the dyno with a set of aftermarket pipes and their Thunder air intake. I firmly believe the Caddman mod breathes at least as good (possibly even better - but theres no proof) than any of the big name aftermarket air mods. Considering the Meanies typically put down around 65 RWHP stock, a 10 RWHP increase is a 15% increase in rear wheel power.

You definitely need aftermarket pipes to get the greatest benefit of it. As for the sound, all cold air intake kits are going to sound roughly the same (I have heard some people complain that some of the Hypercharger kits have a slight whistle to them), but once you ditch the stock pipes, you wont be hearing the intake much.

[joecruiser]

I really wouldn't mind the sound and can probably live with a cold blooded bike. But my mileage just sucks-and those are with conservative TFI settings. If I lower the pods any more, I might as well just turn them off.

[Treym]

Gas mileage? What's that? My daily driver gets 10 MPGs. I don't mind
losing a little to gain what it seems to have done. With my pipes I really don't hear a whole lot of difference. There is a large sucking noise but I love it!!!!!!!

[Hellbilly]

I've got an 05 Classic 1500 Fi. I've added a PCIII and Cobra Classic Slashcut pipes, and I have a K&N installed in the stock setup. I plan to do the Caddman mod on my right side only, and either block off or remove the crossover pipe so I can mount my ignition on the left side as it was on my 03 Honda Shadow ACE 750.

My quesiton is:
Tonight I measured the base of the chrome cover on the right side. It's about 8.125" (8 3/8"). How does that 9" filter fit on there? Does it rest on the rim? Might I be better off with the 8 1/2" filter as in the Coyote mod? http://www.gadgetjq.com/coyotekitmod...structions.htm

I have an appointment to have the bike dyno'd next month at Manley Cycle. When I spoke with Tom Manley, he said I should go for at least the same surface area as the stock filter. The stock filter is 6.75x2" which gives it a surface area of 13.5". I plan for a minimum of 50% increase, so either an 8.5x2.5" (57%), or 9x2.5" (50%).

I'm eager to go forth with this modification, but want to be sure of what filter to buy in advance.

PS Has anyone considered one of these covers?
http://www.knfilters.com/universal/X-stream.htm
Talk about surface area!

[Constrictor]

Originally Posted by Hellbilly

I've got an 05 Classic 1500 Fi. I've added a PCIII and Cobra Classic Slashcut pipes, and I have a K&N installed in the stock setup. I plan to do the Caddman mod on my right side only, and either block off or remove the crossover pipe so I can mount my ignition on the left side as it was on my 03 Honda Shadow ACE 750.

My quesiton is:
Tonight I measured the base of the chrome cover on the right side. It's about 8.125" (8 3/8"). How does that 9" filter fit on there? Does it rest on the rim? Might I be better off with the 8 1/2" filter as in the Coyote mod? http://www.gadgetjq.com/coyotekitmod...structions.htm

I have an appointment to have the bike dyno'd next month at Manley Cycle. When I spoke with Tom Manley, he said I should go for at least the same surface area as the stock filter. The stock filter is 6.75x2" which gives it a surface area of 13.5". I plan for a minimum of 50% increase, so either an 8.5x2.5" (57%), or 9x2.5" (50%).

I'm eager to go forth with this modification, but want to be sure of what filter to buy in advance.

PS Has anyone considered one of these covers?
http://www.knfilters.com/universal/X-stream.htm
Talk about surface area!

I was under the impression that all of the 1500 and 1600 Kaw bikes could benefit from this mod. Since i dont have the bike you have, I cant honestly give you a good answer. Hopefully someone with the same bike will come along and give you some firsthand experience.

[Xlr8n]

Hellbilly- If I am understanding your post correctly, you need to use the Spectre or Mr Gasket 9" filter and chrome lid assembly, not just the filter. This 9" lid and filter replaces your factory lid altogether. The other option is the coyote mod you mentioned which retains the stock lid.

[Hellbilly]

Due to the mounting point in the center of the air cleaner base I couldn't measure straight across, so I measured the base of the air cleaner cover. The two parts fit together so basically they're the same size, right? The measure I got was 8 3/8" (8.375 not 8.125, my math was wrong above).

So I'm wondering how a 9" filter fits on there. Is it supposed to fit neatly inside, or does it lay right on the rim of the cleaner base?

Constrictor, what was the inside diameter of your Spectre filter? K&N has both 7 1/2" and 8" inside diameter available on the 9" filter. I want to use the K&N cotton based filter because I'm under the belief that this will be better in case of rain.

Maybe I just measured wrong. I think tomorrow I'll just cut out some cardboard circles at 8 1/2" and 9" and see how they lay on there. I would like to go with the 9" K&N, because I prefer their cover over the Moroso (for the 8 1/2"). It would be nicer to find a cover with no logo (anybody?).

On another note, I've read the warning about using silicone sealant near gasoline. I am only going to mod the right side and remove the left side completely (as in the Coyote mod). I plan to seal off the air opening in the right side. Is there a better sealant to use than silicone since it is going to be so close to the throttle body? Or is silicone okay as long as it is completely dried before assembly, even on that side? I guess the question is one of whether gasoline fumes will break down the silicone?

TIA everybody. Thanks for the responses Constrictor and Xlr8n

[Xlr8n]

Originally Posted by Hellbilly

So I'm wondering how a 9" filter fits on there. Is it supposed to fit neatly inside, or does it lay right on the rim of the cleaner base?

I would like to go with the 9" K&N, because I prefer their cover over the Moroso (for the 8 1/2"). It would be nicer to find a cover with no logo (anybody?).

1. Yes, the filter sits right on top of the rim.
2. The Spectre and Mr Gasket chrome lids are both plain. You can use a K&N prefilter over the paper or cotton type filters to help shed water. The make them in a 9" in several different colors. Here's a link: http://www.knfilters.com/wraps.htm

[deniska]

I am thinking of doing this as well. My questions were similar -- is there a better-looking cover? I've seen the K&N one and the Spectre one -- the K&N looks a little better, but both look a little cheapish. Has anyone found a better one?

I was actually contemplating using the existing cover and cutting holes in it (I can make it looks nice), but it doesn't look like any filter would fit inside the existing cover and still go around the solenoids... Has anyone thought about this approach?

Thanks.

[Hellbilly]

Check eBay for covers. I'll PM you with the details on a couple (in case others here are bidding). I went with the K&N and got it for $4, $11 after shipping! Gotta love eBay!

Thanks for the info Xlr8n. You're right about the fit, which I found out with my cardboard template. I don't believe it would be possible to use the 8 1/2" as with the Coyote mod. In that mod, the bike was carbed. The backing plate on the FI has a big plastic support toward the bottom half that I don't think will allow the inside diameter of the 8 1/2".

My 7 1/2" inside diameter template seemed snug on the ICSs. I think I'll pull them out and see how that looks. I really want to go with something over 2" in height. I figure 9x2" only gives a 33% increase in surface area over the stock filter. I'd like 50% or better (>= 9x2 1/4"). But with the higher filter, I want it to have more solidity than the 8" (inside) looks like it would have. We'll see.

Anyone have any ideas for a better sealant than the silicone on the right side? Or is silicone okay as long as it is perfectly dry before assembly? I don't know whether the fumes will break it down or not.

[deniska]

Thanks. Got the covers...

[Xlr8n]

The solenoids are just mounted on thin metal tabs that can be both be bent inward to get a little more clearance. You may end up unhooking/removing the solenoids anyway as they make quite an annoying ticking sound that is pretty loud thru the open element filter.

[bigjohnyeti]

I`ll be doing this mod tomorrow after work,got everything ready,including the homemade knobs made from kitchen faucet handles,with buffalo head nickles where the "H" and "C" plastic inserts would go,with the 8mm studs epoxied in.
Constrictor-in your writeup,which is more than superb,you mentioned that your starting value of the resistor was 680 ohms,that you`d see if it was close when it stopped raining....What was the final value you ended up with?
I`m running stock exhaust with the baffles taken out,maybe you could offer a starting point so I can run down to Radio shack.I`ve already bought 680 s and 1K resistors.I`d rather err on the side of too rich rather than too lean,but what has been the most common value people are ending up with?
Thanks,
John

[Ray-Ray]

Hey Constrictor,

Great tutorial! I just did the install and I'm really happy with the results. I definitely noticed an increase in power after remapping my power commander to run a bit richer. One thing though, trying to find the right size marbles to plug up the hoses must not be as easy as it used to be. I opted to remove the solenoids altogether so I needed to cap three hoses. Instead of marbles, I invested 75 cents at the local ACE Hardware store and bought 3 rubber, cone-shaped plugs along with the 38mm studs.

Maybe this will come in handy for others who are just as marbley-challenged.

[Constrictor]

Sorry for the delay in getting back. I havent had much time for Internet browsing lately.

Bigjohn, I ended up sticking with the 680 ohm resistor. I definitely notice an increase in power with it, and I havent had any bad smoke, or excessive pinging (at least no worse than stock). I checked my plugs right before I put the bike away for last winter and they looked fine. They showed no signs of early detonation. I feel very confident that 680 is fine for my application. I am sure I could have went with a 1k too and not had a problem. If you love in a hotter climate, you might want to go with the 1k. If youre in a colder area like me, and will be doing some rides at 40-50 degrees, you might want to stick with the lower value.

Ray-Ray, I wasnt able to find a marble that fit perfectly either. I used one of those decorative glass marbles you see in the bottom of some vases. It was a tad too small for the hose and would keep falling out, so I wrapped the marble with electrical tape to make it bigger and shoved it in the hose and now its very tight. Your idea sounds like a winner too. Basically anything you can find to block off those hoses will work!

[bigjohnyeti]

I did the mod the other day,and it seems to have added some response,although I haven`t really tried to wring it out.I used the 680 ohm resistor in there and right now it appears to be fine,no popping,fluttering,etc.I`ll pull the plugs this coming weekend after I get some miles on her.
It looks good with the Mr Gasket tins on it with the homemade knobs with the Buffalo nickel inserts.As I mentioned in another thread,with the two big round air filters on the sides,it reminded me of star wars` princess Leah with the two Danish buns on her ears,so I christened my Meanie " Princess Leah"
John

[NY_Guy]

Mike:

I read (in this forum) that the stock right side cover can be used-- but maybe that's only with the Thunder air kit. Is there a way to add an air cleaner element on the right side, leave the left side alone, and still use the stock right side cover? Thanks.