Suzuki TLS

[Gixxerthou]

How to modify your Airbox (TL1000S):

1)

Remove the Airbox.This photo shows the area where the flapper valve solonoid used to be before removal.

2)

This is the view looking down at the what used to be the flapper valve solonoid. Note how little material is on the left side. Be careful not to remove too much.

3)

This is the stock air filter opening.

4)

This is the filter opening after it has been opened up. Make the opening flush with the air filter.

5)

This is the view with the filter in place (Photo taken from below). Note how you can only open up approx 1/2 of the filter. This is due to the design of the frame, and the way the airbox wraps around it.

6)

This is view of the entrance from the extention tube on the right side of the bike. Compare this picture to your stock airbox to see how much material to remove. It isn't much.

7)

A new foam gasket on a ported extention tube. This is nessessary to seal the extention tube to the new airbox floor you will make. Use a 1/2" foam gasket.

[Gixxerthou]

continued:

8)

This is the new airbox floor made out of sheetmetal. I used ventilation ducting and cut it to fit. The sheetmetal is pop-riveted in place and sealed with RTV silicone.

9)

This is another view of the new airbox floor. Note how the rivets are sealed with silicone. I also sealed the rivets on the inside of the airbox even though it isn't shown.

10)

Note how the sheetmetal wraps around the entrance to the airbox. This surface is very irregular, and needs a good seal to keep the ram air functional.

11)

This is the view of the new airbox floor from inside the airbox. Note how the sheetmetal is sealed to the plastic with silicone. Remember to seal the rivets, even though they aren't in this picture.

thats all there is to it... Should liberate a few extra ponies so long as everything is sealed correctley.

Copyright The Thumperzone 2008