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

[RichLockyer]

On the 1600, the K&N fits and seals flawlessly.

[NY_Guy]

Originally Posted by JoeJoe

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

George at Dobeck Performance, Trent at Thunder, the service manager at Blockers (a large PA dealership), and other "experts" have told me that due to detergents and additives in gasoline today, plugs look leaner than they actually are. But plug color was how us "old guys" used to check air/fuel mixture on 4 cycle bikes.

After I had my 2000 Nad dyno tuned last summer (at 14:1), I pulled the plugs and they looked way too lean-- but I can't really argue with the O2 results. So that seemed to confirm what I'd heard about detergents, etc. As a result and to put this issue to rest for me, I ordered and today installed an NGK O2 monitor and will have the sensor welded-in when the weather improves (enough to ride up to Peekskill). This little baby reads a/f ratios to the hundredths, from 9 to 16:1.

I’ve also ordered a handlebar mount for the monitor from JC Whitney, but in the meantime, black duct tape will have to do (see pic). The wiring harness is 13' long, so I had to cut, solder and wrap. When I get results, I’ll post. (BTW: My TFI settings now are 3, 5, 4 and 9 and the plugs’ ceramic insulators are light grayish-amber.) To be continued….

[CaddmannQ]

Originally Posted by SUPERSTRUT

... 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 been thinking about a mod like that for some time, as I think just raising the filter maybe 3/16" further from the backing plate will smooth the airflow through the throttle body.

So far I haven't found just the right stuff to do it with.

[PO-POMAX2K]

Joined the caddman club and thanks to Phatboy I'm running a custom Map!

[NY_Guy]

Originally Posted by PO-POMAX2K

Joined the caddman club and thanks to Phatboy I'm running a custom Map!

I like the looks of the K&N filters on both sides. I added one on the right side only so I can cover it in heavy downpours. I bought a K&N "prefilter" (doesn't keep out water) and put 2" black duct tape over the center, so when it rains, the right side is covered. I put the cover on w/ the engine running and it made very little difference in a/f ratio (like .5). I thought it would be much richer. But I recall a dyno graph comparison of Thunder air kit with Caddman with stock, and the Thunder generated 7 additional hp over Caddman (I think John Lawrence posted-- Gadget). Funny how a smaller filter (7") can generate more power? Maybe it has something to do with air velocity?

[joecruiser]

Well, it appears a lot of you have had great success with this mod. I tried it awhile back but went back to stock after my mileage took a nose dive. I've read some post that claim that it is suppose to improve gas mileage. I might have to re-discover this mod and spend more time with the tunning aspect of it. I would go as far as getting it dyno-ed to maximize the TFI. I kind of like the Thunder base plate kit NY Guy refered to. It makes the install look much cleaner and seems it would reduce a lot of turbulance.

BTW - Do any of you get any flack from the service department when you take a bike that has been modified this way in for service?

[bross]

Originally Posted by joecruiser

BTW - Do any of you get any flack from the service department when you take a bike that has been modified this way in for service?

If you do I would find another shop. All the shops around here are happy to install mods like this, they'll happily charge you dyno time.

[Xlr8n]

Originally Posted by joecruiser

Well, it appears a lot of you have had great success with this mod. I tried it awhile back but went back to stock after my mileage took a nose dive. I've read some post that claim that it is suppose to improve gas mileage. I might have to re-discover this mod and spend more time with the tunning aspect of it. I would go as far as getting it dyno-ed to maximize the TFI. I kind of like the Thunder base plate kit NY Guy refered to. It makes the install look much cleaner and seems it would reduce a lot of turbulance.

BTW - Do any of you get any flack from the service department when you take a bike that has been modified this way in for service?

The nice thing about the Cadmann is that you can switch it back to stock in less than a minute when you want to take it in for service.

[CaddmannQ]

Originally Posted by NY_Guy

... I recall a dyno graph comparison of Thunder air kit with Caddman with stock, and the Thunder generated 7 additional hp over Caddman (I think John Lawrence posted-- Gadget). Funny how a smaller filter (7") can generate more power? Maybe it has something to do with air velocity?

7 HP? Not at all.
Here's the chart.

http://www.kawasakimotorcycle.org/fo...g?d=1157383074



The graph showed the Caddmann with stock pipes, compared to a Thunder with Vance & Hines pipes. There's almost no difference with equal setups, but with the Thunder it has perhaps a 1 hp advantage based on comments by Top Dawg, after testing his VN1600 with both setups. (He had a Pro-pipe rather than baggers though.)

I do not know anyone that has done an exact test of both setups, but the difference probably isn't enough to really notice.

My gas mileage went down slightly on the highway and about 10% in town, but recovered when I installed a taller reat tire. With more power you pull that tire with ease & the engine turns slower.

[CaddmannQ]

Originally Posted by NY_Guy

I like the looks of the K&N filters on both sides. I added one on the right side only so I can cover it in heavy downpours. I bought a K&N "prefilter" (doesn't keep out water) and put 2" black duct tape over the center, so when it rains, the right side is covered. I put the cover on w/ the engine running and it made very little difference in a/f ratio...

I've ridden in some very heavy rains now, with both filters open, and had no problem.

I went through a heck of a storm on Tioga Pass (almost 10,000 ft. elevation) this year, and there was an inch of water standing on the road.

The air is thin up there, and the rain was the heaviest I've ever ridden in, in 35+ years of riding. Lack of visibility limited me to 25 MPH at points, but the bike ran without problems, and still has the same elements on it 2000 miles later with no noticible degradation.

I actually got soaked 4 times that day, going from Fresno, CA to Topaz Lake, NV. The bike never faltered.

[Tod]

Anyone ever thought of possibly cutting a larger diameter aircleaner cover into maybe a semicircle, or wedge that would sheild the front/top of the element without restricting airflow?

Crude attempts at examples below:

Say, something that starts out like this...


And ends up like this...


Or this...

[RichLockyer]

If anything, I would want to shield the BACK, rather than the front.
Shielding the front would end up drawing against the intake at high speed.

[Ray-Ray]

I've had this mod in for a 4000 thousand miles and haven't had any problems at all. It's works great and I still get those puzzled looks! Thanks again, Constrictor.

I'm running a Power Commander III on my 1500 Classic Fi. I posted map in this forum along with my findings for those who may not want to go through the same tweak-and-ride experience as I did.

Happy Riding,

[CaddmannQ]

Right on! Another convert!

[CaddmannQ]

Originally Posted by RichLockyer

If anything, I would want to shield the BACK, rather than the front.
Shielding the front would end up drawing against the intake at high speed.

Man, it's hard for me to think exactly what might happen without some kind of air tunnel test, or a real road test.

You'd probably create a bunch of turbulance, but with the large surface area of the filter, even that may have little effect on performance.

The turbulence might, however, cause more water to enter the filter instead of less. Air is funny like that. A tiny little deflector might deflect more water than a big cover.

But, I'll tell you: if I ever get caught in a rain heavier than the one I rode through on Tioga, I might be just as happy if the bike stalled out so I could pull over under a tree!

(Except for the lightning. Lots of bikes were parked under trees and I kept going. Not just because I wanted to "get there" (Topaz) but because I was taught to never get under a tree durring lightning. )

[PO-POMAX2K]

Look familiar? Sorry if this is a repost.

Arlen Ness:

[bigjohnyeti]

Hmmmmmm,this has me thinking....Instead of spending ungodly dollars for a plain round piece of chrome,can`t someone try to figure out how to adapt an aftermarket auto filter setup,like about 9"x2",and install it along with a half inch marble and ,while he`s at it pull the plugs offa the two solenoids and accomplish the same end? Then,with the money he saves,buy a TFI unit.
Does this idea sound like someone oughta explore further?Hah?
LOL
John

[Xlr8n]

Originally Posted by bigjohnyeti

Hmmmmmm,this has me thinking....Instead of spending ungodly dollars for a plain round piece of chrome,can`t someone try to figure out how to adapt an aftermarket auto filter setup,like about 9"x2",and install it along with a half inch marble and ,while he`s at it pull the plugs offa the two solenoids and accomplish the same end? Then,with the money he saves,buy a TFI unit.
Does this idea sound like someone oughta explore further?Hah?
LOL
John

I think you're onto something there! We can call it the Yeti mod!

[bigjohnyeti]

Yeeeeaaaaaahhhhhhh !!That has a real nice ring to it !!!



or is it a clunk?
John

[CaddmannQ]

Gee, the Ness "Big Sucker" sells for $200 each. Just one element alone is $45, which is more than the entire cost of my dual Caddmann setup. I'd say that anyone that pays $200 is the "big sucker!"

Plus you only get one 8" filter from Ness, and Caddmann gives you two huge 9" filters!

That must make the Caddmann Kit the MUTHER OF ALL SUCKERS!