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

[NY_Guy]

No need to respond-- I found the answer to my question at http://www.gadgetjq.com/thunder+stock_acmod.htm.

[bigjohnyeti]

I pulled my plugs today after a coupla hundred miles with the mod,using the 680 ohm resistor,and they were right on the money,light brown,no glaze.
Today I also emptied my spare goat`s belly,gonna have a friend weld it back together for me so I can replace my stock one.That way I`ll be running it with my stock hollowed out mufflers,hoping it`ll sound a bit more aggressive.It should also give me another hosspower or two....
John

[Hellbilly]

I got my setup all together, but when I put it together, I noticed that there is a small gap at the top part. The plastic is raised out a little around the intake holes and the filter is sitting on that. I don't want to file them down. Is this because I went with the 7 1/2" inside diameter, or has anyone else noticed this? What did you do? Any suggestions? I did try shaving the rubber down a little on the filter, but that didn't seem to work. I might try some weather stripping.

PS: When my K&N filter arrived from the mfr, I noticed quite a bit of small rubber shavings and even a couple of peices of screen material inside the filter. That would be pretty bad if it got sucked into the engine. It would be good to thoroughly inspect the filter before installing.

[bigjohnyeti]

That`s what you get for buying `spensive stuff...lol I went with the Mr Gasket 9 inch and it fit like socks on a rooster.No gaps,filings,shavings,you shoulda gone with the cheap ones.
Seriously,I didn`t run into that problem,I dunno what to tell you.Maybe someone else can contribute a meaningful solution and help you out.
John

[Hellbilly]

Originally Posted by bigjohnyeti

That`s what you get for buying `spensive stuff...lol I went with the Mr Gasket 9 inch and it fit like socks on a rooster.No gaps,filings,shavings,you shoulda gone with the cheap ones.
Seriously,I didn`t run into that problem,I dunno what to tell you.Maybe someone else can contribute a meaningful solution and help you out.
John

Looking at it again, it seems the base is recessed a little. I put a thin piece of weatherstripping in there that I think will do for the time being.
The bike is going on the dyno this week. I'm dropping it off tomorrow. I'll post the results!

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Why aren't my images showing?

[deniska]

I am having trouble finding filter elements! Went to three stores in my area -- nothing on the shelf. They can order K&N elements -- no thanks. I wanted to find the Spectre 48059 -- that's the slightly more expensive cotton fiber white element. Called two stores -- they can't find the part number. Looked for stuff online -- nothin'. I did find 4805 online (the 7.99 plain). I guess that means living in the boonies.

Where do I buy this stuff?

[Xlr8n]

oops double post.

[Xlr8n]

Originally Posted by deniska

I am having trouble finding filter elements! Went to three stores in my area -- nothing on the shelf. They can order K&N elements -- no thanks. I wanted to find the Spectre 48059 -- that's the slightly more expensive cotton fiber white element. Called two stores -- they can't find the part number. Looked for stuff online -- nothin'. I did find 4805 online (the 7.99 plain). I guess that means living in the boonies.

Where do I buy this stuff?

deniska-Most parts places only stock the cheaper paper filter but any of them should be able to order the cotton style for you. Here's their catalog with part numbers. Click on the style you want and then click 'stocking dealer' and enter your zip code to find a possible supplier. Hope this helps. http://www.powerflowracing.com/prdlist.asp?PG=2&PSG=8

[deniska]

Thanks. AutoZone store didn't want to take an order over the phone, but I found it on their web site.

[BigJohn]

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 believe that he did. He then had Robin dynoed. She runs REAL nice now....

[NY_Guy]

Originally Posted by bross

Thanks strictor and caddman, I've been running a K&N for awhile now and just did the resistor mod so will see how it runs. Great right up, made it a very simple mod.

Brent: Do you use the 9" K&N (Part No. E-3527). How well does a 9" filter seal on the right side against the stock intake plate (which is about 8" in diameter)? I'm still not clear on this (no matter which filter is used): does the 9" filter overlap the stock intake plate and, if so, how well does that seal, since the stock plate wasn't designed to accept a filter in this manner? Thanks.

[bross]

Originally Posted by NY_Guy

Brent: Do you use the 9" K&N (Part No. E-3527). How well does a 9" filter seal on the right side against the stock intake plate (which is about 8" in diameter)? I'm still not clear on this (no matter which filter is used): does the 9" filter overlap the stock intake plate and, if so, how well does that seal, since the stock plate wasn't designed to accept a filter in this manner? Thanks.

I'll run out and check it tomorrow, my dealer just sold it to me as a replacement for the stock filter so it seals the same. I'll see if I can find the part # on the filter for you tomorrow.

[NY_Guy]

Originally Posted by bross

I'll run out and check it tomorrow, my dealer just sold it to me as a replacement for the stock filter so it seals the same. I'll see if I can find the part # on the filter for you tomorrow.

Brent, no need to do that-- I thought you were using a 9" round filter on the right side (like Raybro 57 posted on Gadget's web site). I'm just trying to figure out how peoople SEAL the right side 9" filter against the stock intake plate. With the Thunder and other air kits, the replacement plate has a lip on it the filter fits inside. With the Caddman, as I understand it, the filter simply sits on top of the stock intake plate, and I don't think it's meant to seal on that surface (but I've been wrong before). Any suggestions out there?

[Nanuk]

I think it seals just fine. Its only atmospheric pressure after all.

[Constrictor]

Trust me, if you had a leak around your filter, you would know it. Any vacuum leak would result in an abornmally high idle. If your bike is idling fine, then you dont have any leaks.

[NY_Guy]

I'm leaning towards the Raybro mod from Gadget's web site (http://www.knfilters.com/search/prod...x?Prod=60-1070) with K&N 9" filter. Has anyone else done this to an 05/06 Nomad and, if so, does the K&N filter fit snugly against the stock intake plate? Or does the Mr Gasket or Spectre filter have a better seal? I looked at BigJohnYeti's Caddman today (using Mr Gasket 9" filter) on his MS and the fit was great.

[Xlr8n]

The base plate has a completely flat lip around its perimeter. You need to bend the solenoid mounting tabs in just a tad so the filter element will keep it's shape. the center depression on the filter lines up perfectly with the baseplate. I run the spectre paper filters with a K&N pre filter cover. After mounting it up and letting it set overnight, remove it and you can see the groove in the filter rubber where it is completely sealed. Hope this helps.

[NY_Guy]

After reading everything I could on the subject, I've finally made a decision (trumpeting sounds in the background): I ordered the K&N (http://www.knfilters.com/search/prod...x?Prod=60-1070) with a pre-filter and will keep the ICSs intact. With the present setup, I've already increased my TFI #2 pot to 4:00 position, and will have to richen it up some more after the new filter install.

I'll give George a call at TFI, since he's been very courteous and helpful in the past, then post the results here. If anything like the Thunder kit I installed on the 2000 Nad, this should be quite an improvement (though my gas mileage is not great, getting about 140 miles before filling up). I did call K&N to see if they sold separately a round rubber seal (with adhesive on one side) to make contact with the stock intake plate better, but NO (John Beluchi sneer) they don’t!

[NY_Guy]

Originally Posted by Xlr8n

The base plate has a completely flat lip around its perimeter. You need to bend the solenoid mounting tabs in just a tad so the filter element will keep it's shape. the center depression on the filter lines up perfectly with the baseplate. I run the spectre paper filters with a K&N pre filter cover. After mounting it up and letting it set overnight, remove it and you can see the groove in the filter rubber where it is completely sealed. Hope this helps.

Thanks, yes it was very helpful (I just forgot to say so!). What a remarkably simple solution to a relatively complicated machine!

[JoeJoe]

I just did this mod. to my vz1600. Runs great. I seem to have a rough spot between 2-3000 RPM. Cruising speed. I have v&h big shots with a powercommander. Manny from dynojet suggested the map I should use. He said that most intake map the same. Used same map as the Thunder Man. tornado. I just want to make sure I am not running to lean. Has anyone had their bike dyno tested & mapped for a powercommander. Thanks!

PS- I was also told checking my spark plugs was no longer an accurate way to check if I am running lean. I was told the reason was because of all the fuel additives today. Most bikes run a lighter spark plug to begin with. Anyone else heard this before? Thanks!

Mods that I did - Marblized, unhooked solenoids (green wire), removed snorkle from left side. Pretty easy. Hope I didn't miss anything. Thanks!

JoeJoe