Results 1 to 15 of 15

Thread: Oil in the airbox Mk. 2

  1. #1
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    206

    Oil in the airbox Mk. 2

    After my Futura started running rough a couple of months ago, i decided to take it apart and redo the vacuum lines and the CBR coil mod (+Magnecor leads).

    Since I had it apart anyway, I decided to do the kzmille/Hansb crank case breather mod to eliminate oil in my airbox. However, kzmille's mod (see here) can't be done on the Futura due to the stepper motor (IAC). Hans (see here) just moved his stepper motor to the other side of the airbox (drilled a hole, plugged the original).

    I decided that the filter didn't have to be the full size of the depression on that side of the airbox. I created a bracket that was only half the size of the depression and then used oil-proof gasket maker (Permatex Ultra Black) to seal the lower portion so oil couldn't seep into the IAC port.

    I used the following parts:


    • 1 - 1/16" aluminum plate
    • 1 - SV650 FILTER,BREATHER (#12: http://www.bikebandit.com/oem-parts/...9780#sch509785)
    • 3 - 10-32 1/2" screws + washers and nuts
    • 1 - Permatex Ultra Black gasket maker
    • 1 - JB Weld epoxy
    • 1 - Tefen Nylon 5/16" 90 fitting (Amazon)
    • 1 - Tefen Nylon 5/16" to 3/16" straight fitting (Amazon)
    • 1 - 10' 4mm silicone hose (ECU connection)
    • 1 - 10' 8mm silicone hose
      • 1- very short ECU connection
      • 1 - crank case breather (to be replaced with ASH hose)
      • 2 - IAC hoses (to be replaced with ASH hose)


    Note: I plan on replacing the IAC hoses and the crank case breather hose with some ASH flourosilicone versions in the next week or so.

    First, I cut the airbox plastic in two places. The first was the original oil drain plug that isn't needed anymore (small nub on the outside). I cut that off and sealed the hole with some JB Weld.

    Click image for larger version. 

Name:	IMG_0516.jpg 
Views:	108 
Size:	368.5 KB 
ID:	273632
    Click image for larger version. 

Name:	IMG_0528.jpg 
Views:	128 
Size:	289.3 KB 
ID:	273633

    The second is the old ECU connection nub on the inside of the depression. I used a Dremel for this.

    Click image for larger version. 

Name:	IMG_0518.jpg 
Views:	60 
Size:	299.4 KB 
ID:	273635

    It's hard to see in the picture, but I also cut the edge of that plastic ridge back so that the bracket would fit flush against the bottom of the depression close to the stepper motor mount.

    Click image for larger version. 

Name:	IMG_0517.jpg 
Views:	82 
Size:	298.3 KB 
ID:	273636

    After that, I created a template using the cardboard (from the box of the filter, heh). I cut it to size and marked where the holes should go for the screws. I think I went through three iterations before I was satisfied with how it looked.

    Click image for larger version. 

Name:	2. cardboard_template2.jpg 
Views:	88 
Size:	370.7 KB 
ID:	273627

    Note: a PDF of the template is available in post #8 below.

    I then transferred that to the aluminum plate and bent it to shape.

    Click image for larger version. 

Name:	aluminum_plate_prehole.jpg 
Views:	78 
Size:	287.9 KB 
ID:	273628

    I also drilled three holes in the top of the plate for airflow.

    After that, I originally cut a fiber air filter to size and shape, but the airflow (as Hans mentions below) was not very good.

    Click image for larger version. 

Name:	filter.jpg 
Views:	65 
Size:	347.6 KB 
ID:	273630

    So, I replaced the fiber air filter material with actual breather filter material from an SV650 (See post #9 below).

    I then mounted the plate into place and sealed it with the gasket maker. I also sealed the screw mount holes with the gasket maker so they were air tight.
    Last edited by infrasoundxp; 12-13-2015 at 07:31 PM.

  2. #2
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    206
    Once the plate was mounted into place, I worked on the hoses.

    This is a view from the right-hand side of the engine. You can see the crank case breather going through the throttle bodies in the back there. Also, the crank case breather required a 90
    nylon connector to get the angle on the hose correct (no low spot).

    Click image for larger version. 

Name:	IAC_crankcase.jpg 
Views:	189 
Size:	335.6 KB 
ID:	273640

    This is the view on the left-hand side of the engine. You can see the crank case breather coming through the throttle bodies to connect to the engine.

    Click image for larger version. 

Name:	through_throttle_bodies2.jpg 
Views:	120 
Size:	331.8 KB 
ID:	273641

    This is another view on the left-hand side of the engine. You can see the new location of the ECU connection on the airbox (switched with the crank case breather connection). It's a short length of 8mm hose to the 5/16"-3/16" fitting to the 4mm hose down to the ECU.

    Click image for larger version. 

Name:	ecu.jpg 
Views:	233 
Size:	373.1 KB 
ID:	273639

    I also did the FPR mod at the same time. If you don't want the FPR mod on your bike, you will also need a 3/16" T connector to tie into the 4mm ECU line for the fuel pressure regulator.


    Last edited by infrasoundxp; 02-25-2015 at 03:21 AM.

  3. #3
    apriliaforum Junkie drd's Avatar
    Join Date
    Jan 2004
    Location
    America's Mongolia
    Posts
    266
    Looks great! Are you able to scan the template and create a pdf?
    Don


  4. #4
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    206
    I'll try to get a actual-size PDF created so it's easy to print out.

  5. #5
    apriliaforum Junkie Hansb's Avatar
    Join Date
    Jul 2003
    Location
    Norway..bloody north
    Posts
    460
    I am not sure it will be good air flow with your filter material. Be aware that your filter is filled with oil after a few hundred km.
    A V60 engine have a big change of crankcase volum in a cycle, so the filter must easy let the air flow pass. You can blow a gasket or the
    water pump seals. I made my filter from 10 m 0,8mm steel wire just to make sure the air flow good.
    This was done last winter. About 8000km last summer, and no oil at all in the air box.
    Hans

  6. #6
    apriliaforum Junkie
    Join Date
    Aug 2004
    Location
    Cross Plains, WI
    Posts
    258
    I sent mine to atmosphere with a long hose and K&N crank filter. So far no need for an inline catch can.

    Philip

  7. #7
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    206
    Quote Originally Posted by Hansb View Post
    I am not sure it will be good air flow with your filter material. Be aware that your filter is filled with oil after a few hundred km.
    A V60 engine have a big change of crankcase volum in a cycle, so the filter must easy let the air flow pass. You can blow a gasket or the
    water pump seals. I made my filter from 10 m 0,8mm steel wire just to make sure the air flow good.
    This was done last winter. About 8000km last summer, and no oil at all in the air box.
    Yeah, I just followed kzmille's post about where he got his filtering material. I can check airflow after a few months to make sure that it still has good airflow.

  8. #8
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    206
    Created a PDF from the cardboard template. I tested it with US letter printing at 300dpi and without "fit to page". Not sure if it will work for A4, but I assume it will.

    I included a mm ruler on one side so you can confirm that you printed it to the correct size.
    Attached Files Attached Files

  9. #9
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    206
    I was concerned about the airflow, so I bought the breather filter for a Suzuki SV650:

    http://www.bikebandit.com/oem-parts/...9780#sch509785

    #12 FILTER,BREATHER

    The very first layer of the previous fiber material was completely matted with oil, so it was probably good that I switched out the type of material.

    I cut it up, and installed it in place of the fiber material I had originally. I only had to cut up two pieces (one top, one bottom) with how thick it was.

    Click image for larger version. 

Name:	sv650_filter_breather.jpg 
Views:	37 
Size:	516.5 KB 
ID:	295484

    Click image for larger version. 

Name:	sv650_futura_filter_breather.jpg 
Views:	51 
Size:	508.4 KB 
ID:	295485

    Click image for larger version. 

Name:	sv650_futura_filter_breather2.jpg 
Views:	45 
Size:	491.3 KB 
ID:	295489

  10. #10
    apriliaforum Junkie Hansb's Avatar
    Join Date
    Jul 2003
    Location
    Norway..bloody north
    Posts
    460

    Oil in the air box

    After running 15000km. No oil.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	DSC_1088.jpg 
Views:	21 
Size:	505.6 KB 
ID:	361458  

    Hans

  11. #11
    apriliaforum expert Motech's Avatar
    Join Date
    Aug 2006
    Location
    Santa Cruz, CA
    Posts
    3,157
    Quote Originally Posted by Hansb View Post
    After running 15000km. No oil.
    Well ya, you replaced all your vacuum hoses and restored proper crankcase ventilation.
    No Matter Where You Are, There You Go!

  12. #12
    apriliaforum expert Motech's Avatar
    Join Date
    Aug 2006
    Location
    Santa Cruz, CA
    Posts
    3,157
    Seriously though, with impeccable hose routings, good filter, de-restricted airbox and 2000 Mille intake air boot (the REAL difference maker), I no longer have any oil in box issues whatsoever.

    Course, bets are off if I overfill my crankcase by even a cup and run two-three Sierra days WFO.
    No Matter Where You Are, There You Go!

  13. #13
    apriliaforum Junkie Hansb's Avatar
    Join Date
    Jul 2003
    Location
    Norway..bloody north
    Posts
    460
    My experience is that oil level means nothing.
    Hans

  14. #14
    apriliaforum expert Motech's Avatar
    Join Date
    Aug 2006
    Location
    Santa Cruz, CA
    Posts
    3,157
    Quote Originally Posted by Hansb View Post
    My experience is that oil level means nothing.
    Until you run all day WFO.
    No Matter Where You Are, There You Go!

  15. #15
    apriliaforum Junkie Hansb's Avatar
    Join Date
    Jul 2003
    Location
    Norway..bloody north
    Posts
    460
    Update!
    My air box is still dry, and everything works perfect.
    But it looks like that it means nothing to oil consumption.
    It is just the same as before.
    Hans

Similar Threads

  1. oil in the airbox
    By cdhall in forum RSV Tuono, Tuono R, Tuono Racing, and Tuono Factory (2002-2005)
    Replies: 3
    Last Post: 11-07-2006, 09:44 AM
  2. Oil in the airbox ?
    By mikeinseattle in forum SL1000 Falco Forum (all years)
    Replies: 3
    Last Post: 05-27-2006, 06:10 PM
  3. More oil in the airbox
    By grins in forum ETV1000 CapoNord (2001-2007)
    Replies: 3
    Last Post: 04-05-2006, 01:46 PM
  4. Oil in the airbox
    By kurtw in forum RSV Tuono, Tuono R, Tuono Racing, and Tuono Factory (2002-2005)
    Replies: 2
    Last Post: 02-22-2005, 11:05 AM
  5. Oil in the airbox?
    By Robert Leslie in forum RSV Tuono, Tuono R, Tuono Racing, and Tuono Factory (2002-2005)
    Replies: 5
    Last Post: 11-02-2004, 08:57 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •