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

[bross]

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!
JoeJoe

I think that's a crock, your plugs should always be a good indicator of what's going on in your engine.

[Xlr8n]

agree^^Double crock!!

[Hellbilly]

The base plate has a completely flat lip around its perimeter.

I found that on the 05 1500 Classic at least, the top part where the intakes are actually falls back a little, so it isn't completely flush. I have a small gap right above each of the intake holes, but a couple of inches of weather stripping on the base of the filter seems to have fixed it.

On another note, someone posted this in the VROC newsgroup regarding removing the ICS:

Has anyone else with a FI bike with a power commmander have any problems with idle? I had it dyno tuned at the beginning of March and everything was great until last week. The idle started going up once the bike warmed up. No, I haven't touched the manual idle knob. I took it back to the place where I had it tuned, after talking to the owner a couple of times on the phone, and he told me that he did some research and because I had taken the IAC valves out when I put the Caddmann mod on, the bike couldn't hold its idle (due to the changing temps here in NC). He told me that he would be glad to put it back on the Dyno and set the idle once again, for free, but in order for it to hold, I needed to put the IAC valves back in the intake. I was curious if anyone else has had this problem or had any other ideas? The owner of Iron Thunder Cycles is a very knowledgable guy, and I don't think that he would be shootin' me a line of bull, but I know other people have done this very same mod.

I had intended to post my dyno results here, but after making an appointment almost 2 months in advance (okay, maybe 6 weeks?), I brought my bike in to Manley Cycle on appointment day one week ago and it's still not done. I'll be taking it elsewhere, and I'll post the results when it's finished.

[acamp75]

Does any one know where to get rain covers for these filters and maybe a part #?

[OldStreak]

[PO-POMAX2K]

Finally got around to reading this. I thank You and the wife might not like you too much when I go home and tell her I'm gettin more stuff for the bike(she hasn't ridden with me much since our daughter was concieved)

I have a power commander with supplied maps do you think I could just program the map they have for: "Vance and Hines Bigshots with aftermarket air intake" until I determine if I need a dyno-tune? I'm not sure on the proper title the powercommadner site seems to be having errors.

[Constrictor]

Finally got around to reading this. I thank You and the wife might not like you too much when I go home and tell her I'm gettin more stuff for the bike(she hasn't ridden with me much since our daughter was concieved)

I have a power commander with supplied maps do you think I could just program the map they have for: "Vance and Hines Bigshots with aftermarket air intake" until I determine if I need a dyno-tune? I'm not sure on the proper title the powercommadner site seems to be having errors.

Youre not looking at it from the right perspective...rather than tell your wife that you have more money to spend on mods for the bike, you should be telling her how happy she will be that you are going to be saving about $150 doing this mod as opposed to getting something like a Tornado or Hypercharger! She'll shower your keen shopping skills for saving so much money!

[PO-POMAX2K]

Youre not looking at it from the right perspective...rather than tell your wife that you have more money to spend on mods for the bike, you should be telling her how happy she will be that you are going to be saving about $150 doing this mod as opposed to getting something like a Tornado or Hypercharger! She'll shower your keen shopping skills for saving so much money!

Nice, I already cleared it with her, she's pretty cool about what I spend my night differential on while I'm on nights. Any thought on running the upgraded map? I'm going to order the filters very soon.

[CaddmannQ]

I found that on the 05 1500 Classic at least, the top part where the intakes are actually falls back a little, so it isn't completely flush. I have a small gap right above each of the intake holes, but a couple of inches of weather stripping on the base of the filter seems to have fixed it.

On another note, someone posted this in the VROC newsgroup regarding removing the ICS:


I had intended to post my dyno results here, but after making an appointment almost 2 months in advance (okay, maybe 6 weeks?), I brought my bike in to Manley Cycle on appointment day one week ago and it's still not done. I'll be taking it elsewhere, and I'll post the results when it's finished.

I definately recommend weather stripping around the entire perimeter of the filter, as well as a rubber washer under the wing nut or bolt head that retains the chrome cover. Also be careful when mounting that the filter doesn't distort from round too much, nor fall to low, as it can start to block the airflow to the throttle bodies on FI bikes. (Don't know about the carb modles.)

Hold it up a bit from below as you tighten the nut, and go around the filter with your fingers to make sure it's evenly placed over the backing plate.

Regarding the rain issue, you won't need rain covers in any rain you're likely willing to ride in. I've done two hours in a substantial rainfall with no problems.

There is an article on Gadget's site about restoring the cold idle speed after removing the ICS's. It's simple & only involves putting a rubber or plastic shim over the idle stop stub on the throttle body.

[Spok]

thanks for popping in our little world with your further knowledge on the mod named for you.

[CaddmannQ]

since I am the moderator at Motorcycle USA, it is the Mod named for a Mod.

HehHehHeh....

[RichLockyer]

There is an article on Gadget's site about restoring the cold idle speed after removing the ICS's. It's simple & only involves putting a rubber or plastic shim over the idle stop stub on the throttle body.

Hmm... define "cold"
I put a set of pipes on last night, but didn't have time to install the Fi2000R, and I didn't have the right size caps for the ICS ports.
Finished all of that today, did the AF mod with K&N... bike was obviously dead cold, but ambient was about 85 or so.

Fired right up and didn't stall. If anything, it felt a little less likely to stall when I start getting into the friction zone.

http://personal.linkline.com/rlockyer/vulcan/pipes.jpg
http://personal.linkline.com/rlockye.../caddmanlt.jpg
http://personal.linkline.com/rlockye.../caddmanrt.jpg

[RampRat]

That's far from "cold" it's shorts and T shirt weather

bike was obviously dead cold, but ambient was about 85 or so.

[RichLockyer]

So... this isn't something I'll have to worry about in Los Angeles?

[RampRat]

Ya think

So... this isn't something I'll have to worry about in Los Angeles?

[CaddmannQ]

Hmm... define "cold"
I put a set of pipes on last night, but didn't have time to install the Fi2000R, and I didn't have the right size caps for the ICS ports.
Finished all of that today, did the AF mod with K&N... bike was obviously dead cold, but ambient was about 85 or so.

Fired right up and didn't stall. If anything, it felt a little less likely to stall when I start getting into the friction zone.

Did you ride the bike until the engine warmed fully & adjust the idle RPM to 900?

Once you do this, with the ICS gone, your startup idle at temps below about 70F will be too low to maintain without the knob out, and at temps below 60, even the knob probably won't be enough without Gadget's shim mod.

[RichLockyer]

Did you ride the bike until the engine warmed fully & adjust the idle RPM to 900?

Nahh, but I need to get a tach as I do not plan on paying the dealer $300 to change the oil and tighten some nuts at 600 miles. Right now it's right where the dealer set it at PDI.

[SUPERSTRUT]

I ordered my filters for my bike yesterday. I've already unhooked my ics and plugged the holes. It's kinda strange but my bike seems to run better without the ics. It used to idle at different levels and seemed to change everytime I stopped. Makes me wonder if maybe there wasn't something wrong with my ics from the get go. Anyway, I have already done everything but install the block off plate to the left side, (but I do have it cut out already) and the filters (that I'm waiting on). I saw some rubber gasket at the marine store that I think I'm gonna give a whirl for the filter seal. It's round and made of thick rubber. I think I may buy some and see if I can find a way to attach it to the airbox itself. I'll give you an update.


RIDE ON!!!!!!!!!!!

[RichLockyer]

The problem with the ICS is they are not proportional linear... they are effectively digital... they're a light switch... on or off. That's also why they are so noisy. When it's very cold, they'll be open all the time and quiet, but in the transitory temps (70 or so like Caddman mentioned) they're constantly opening and closing to maintain idle speed.
The tubes that they plug into on the backing plate are throttle plate bypass ports. When the ICS opens, it's the same as cracking the throttle.

More effective/reliable than a bi-metal strip thermostat on a high-idle pin? Perhaps. Smoother and quieter? Heck no.

[SUPERSTRUT]

Well, I got my air filters today. I didn't get a chance to finish putting them on though. I really dislike the way they seal up on the backside. I'm working on a spacer that will fit in the factory seal groove on the backs. If the spacer extends out about a 1/16th past the backplate edge, it should provide enough clearance to keep the filter from getting to close to the intake plenum. It will also allow the filter to have a good level sealing surface without using strips of weather seal. I've rough fabbed one out of heavy gauge banding wire and it seems to seal up perfect. I'll probably have to brainstorm on it a little while, but there's got to be a solution. I'll keep y'all updated.


RIDE ON!!!!!!!!!!!