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emersonsc

ZForce 800 Snorkel
« on: October 28, 2015, 10:31:56 pm »
First of all I wanted to thank NMKawierider for all of his contributions and ideas.

After dealing with some unfortunate airbox issues, I realized that the stock air intake systems on the units are a HUGE weak point. Stock, the inlet of the intake faces the tub of the bed, not that grill you have in the cab. This is bad for many reasons. Most importantly, you're sucking in hot air from the motor, and because the rear wheels on these sit on either side of the motor, that hot air is also very dirty. This leads to an air box and filter that become overwhelmed fast. Depending on your conditions, you may have to clean your filter multiple times during a ride (I tend to go on rides that are a few hundred miles at a time).

At first, I tried one of NMKawierider mods, where you use a intake grill, attach it to the bed, and use a toilet bowl gasket to seal the intake to the grill. It's a great mod AND looks good. For me, the problem is the fine almost baby-powder like sand we have made its way in just as easy, and when it rained it filled the air box up with muddy water. His update to that mod would not work in my situation because the bed area just took on too much road debris especially when it rained.

Out of desperation I started looking at snorkel set ups to see how the typical RZR kits looked and were routed. Since going up through the bed isn't much of an option with these (there's a lot of frame work there), and I didn't want to go up through the bed edges, why not go through the back? I already had an opening for the intake grill mod.

Let me first off say that if you have easy access to ABS pipe and fittings, use it! It's black so you right away save time and money. I did not so I had to go PVC.

My supplies:
2" PVC pipe cut into the following lengths:
7"
20.5"
1.5" (3 pieces)
60 degree elbow
90 degree sanitary elbow (3)
90 degree street elbow
Coupler
2" conduit bracket

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emersonsc

Re: ZForce 800 Snorkel
« Reply #1 on: October 28, 2015, 10:43:35 pm »
First, you'll remove the air grill in the cab, followed by the center cover. Pulling your parking break up will make this easier. Then you'll remove the stock intake tube from the airbox. Loosen the band clamp up all the way and push it back down on the rubber kneck coming off the airbox. You'll then need to cut off the metal bracket that the stock air intake tube bolted to. I left about an inch sticking up so I could weld the bracket back on if I ever needed to. A grinder works the quickest and cleanest.

Next youll DRY FIT the 2" coupler to the 7" senction of pipe. On the other end of the pipe youll attach the 60 degree elbow. On the other end of that elbow you'll attach one of the 1.5" sections followed by a 90 degree sanitary elbow.

The couple end will be going inside the air box rubber inlet tubs. It's a tight fit, so if need be, use some Vaseline. Do not tighten the clamp. Adjust the 90 elbow so that it fits against the tub of the bed. Make sure its centered. Trace around it, then remove the pipe from the rubber inlet. Next, cut your hole. Check to make sure the 90 can go through. This maye take a few times to get the hole big enough for the elbow to pass through. Once your hole is cut right, reattached your piping to the rubber tube, coupler end inside the rubber inlet.

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emersonsc

Re: ZForce 800 Snorkel
« Reply #2 on: October 28, 2015, 11:03:28 pm »
Next, you'll place one of the 1.5" pieces of pipe inside the 90 degree sanitary elbow. From there you'll attach your 2nd 90 degree sanitary elbow, making sure its pointing up. Attach the 20.5" section of pipe to that, and finish it off by attaching the last 90 degree sanitary elbow so its facing towards the back of the unit.

I have a rear windshield, is mounting the pipe any other way will be up to you. For those with rear windshields, you'll want the mount at lease three or four inches from the bottom of the top elbow. Make sure its centered and the pipe is straight, mark it, they drill a hole and use your conduit bracket to mount the pipe to the windshield. Again, make any final twists and adjustments so everything is straight and looks the way you want it. Using a sharpie, make alightment marks on each joint, and number each joint so you don't get them mixed up.

You're going to assemble this into two sections. The first section will be (in this order) the coupler, 7" section, 60 degree elbow, 1.5" section, 90 degree sanitary elbow. The section section will be (in this order), the 1.5" section, 90 degree elbow, 20.5" section, and the 90 degree street elbow.

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emersonsc

Re: ZForce 800 Snorkel
« Reply #3 on: October 28, 2015, 11:28:14 pm »
Painting and Final Assembly

You'll want to sand the sections down with a good rough grit sand paper or steel wool. You'll want to get a self etching primer that's made for plastic. Also make sure your final colour should also be made for plastic. I chose flat black to match the textured black plastic of the bed and roll cage.

On the 2nd section of the snorkel, you'll want to tape off about .5 to .75 of the short section of pipe coming out of the 90 degree sanitary elbow. This ensures you have a clean surface to apply your primer and glue when making the final connection.

The final assembly will consist of attaching the first section to the rubber inlet pipe, then working the elbow through the hole in the bed, once that's in position, tighten the pipe clamp. Get the connection on the elbow and short pipe section prepped, then get your glue on. Fit the pipe through the bracket (I spread the bracket arms out so the didn't scrape on the pipe) make the final connection by attaching the 2nd section to the 1st sections elbow. Align and then tighten the clamp.

I chose to put a cone filter on the end. This is where the final elbow being a street instead of a sanitary is important.

Here is a picture of the final product. I'll get some pictures of the inside connections tomorrow.


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emersonsc

Re: ZForce 800 Snorkel
« Reply #4 on: October 28, 2015, 11:35:07 pm »
Results

First ride out was a major success. I noticed a slight bump in acceleration. I believe this is due to the improvement in positive airflow vs the negative airflow in the bed. With a rear windshield that negative airflow is more apparent.

I'm still debating on adding a 60 degree elbow to the end so its pointing down slightly and ditching the cone filter. I'll have a better idea once I gut some more wet and dry rides under its belt.

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Offline NMKawierider

Re: ZForce 800 Snorkel
« Reply #5 on: October 29, 2015, 07:07:15 am »
Nice! Yeah I was thinking I could always do something like that if mine ever had a problem. From the looks of your bed...you really needed a snorkel anyway...lol
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Tilt windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | Magellan TRX7 GPS

My Videos On YouTube  ...   My Videos On Vimeo

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emersonsc

Re: ZForce 800 Snorkel
« Reply #6 on: October 29, 2015, 07:48:06 am »
Nice! Yeah I was thinking I could always do something like that if mine ever had a problem. From the looks of your bed...you really needed a snorkel anyway...lol

Theyll be some fit and finish to be done too. I think I'm going to use the ring from the screen setup you suggested in your one mod, or I have some other trim rings through our marine parts supplier I might try. I also have another one of those hangers I'm painting so that wont be a shiny eye sore.

What these could really use is some fender flares in the rear. Nothing major like the EX models, but something enough to actually cover the rear wheels.

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Offline NMKawierider

Re: ZForce 800 Snorkel
« Reply #7 on: October 29, 2015, 07:52:47 am »
What these could really use is some fender flares in the rear. Nothing major like the EX models, but something enough to actually cover the rear wheels.
Yeah they sure do...the ones I cut down do work very well. A bit hard to pay over 50-bucks each just to cut down though.

I was thinking of an end for my system but couldn't fine something like this that I could put a filter in. Maybe you would have netter luck.

http://www.ebay.com/itm/Universal-Fit-Off-Road-Replacement-Mudding-Snorkel-Head-Air-Intake-Ram-3-inlet-/331019398653?hash=item4d124b2dfd&vxp=mtr
« Last Edit: October 29, 2015, 07:58:06 am by NMKawierider »
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Tilt windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | Magellan TRX7 GPS

My Videos On YouTube  ...   My Videos On Vimeo

Re: ZForce 800 Snorkel
« Reply #8 on: October 31, 2015, 11:31:37 pm »
Looks good. Are you going to do the CVT? The CVT intake is OK, but the exhaust side is way too low. I raised mine about a foot before the second ride. It's OK now, but I'll do full snorkels as soon I get time.
2015 ZForce 800EX EPS
Two Bros. slip-on
Snorkels
Half windshield
30" Monster mayhems on STI HD2s
2" lift
Secondary clocked to C4
1mm Primary Shim 3.25:1 Lowest Ratio
More to come

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emersonsc

Re: ZForce 800 Snorkel
« Reply #9 on: November 01, 2015, 08:16:36 am »
Looks good. Are you going to do the CVT? The CVT intake is OK, but the exhaust side is way too low. I raised mine about a foot before the second ride. It's OK now, but I'll do full snorkels as soon I get time.

I will eventually. I didnt do this for mud bogs to be honest. I did it because I needed a better intake system than the stock, which has caused me so many issues (and a blown engine after only 600 miles). So far, I've put on close to 200 miles on this and no issues at all. Runs like a champ.

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Offline NMKawierider

Re: ZForce 800 Snorkel
« Reply #10 on: November 01, 2015, 09:41:27 am »
Yeah getting that intake out from under that dirty bed area and putting another filter on it is keeping my airbox clean now too. And being able to seal-off that grill had stopped all that heat, fumes and a lot of engine noise from coming in the cab as well.
« Last Edit: November 01, 2015, 11:57:01 am by NMKawierider »
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Tilt windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | Magellan TRX7 GPS

My Videos On YouTube  ...   My Videos On Vimeo

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emersonsc

Re: ZForce 800 Snorkel
« Reply #11 on: November 01, 2015, 09:49:28 am »
I think if i were to snorkel the CV intake it would only to get that clutch whine and suction noise out of the cab.

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Offline mayor hal

Re: ZForce 800 Snorkel
« Reply #12 on: November 01, 2015, 02:37:52 pm »
Very nice looking mod Emersonsc!
2015 CF Moto 800 ZForce 53"
UNI Air Filter

Gone but not forgotten!

2012 Can Am 650 Max XT
2007 Can Am 500 Max XT

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Offline ACIDICJO

Re: ZForce 800 Snorkel
« Reply #13 on: December 05, 2015, 11:17:48 am »
In looking at how to snorkel the Belt intake I'm running to a issue. It looks like the plastic the tube connects to has a vent on the front side of it. To cerculate the air I imagine idk? Can anyone share any ideas on how to approach this?
2014 ZForce 800 EX
14 in ITP Hurricane's
Sedona Mudder InLaws 30's
2 inch lift
24 inch light bar
2 cube lights
6 inch rear light bar
Wetsounds stealth 10 soundbar
BlueSea Fuseblock
2012 Polaris Rzr 800 all black
2005 Honda Rincon gone but not forgotten

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Offline ACIDICJO

Re: ZForce 800 Snorkel
« Reply #14 on: December 05, 2015, 11:33:09 am »
Here it is off.
2014 ZForce 800 EX
14 in ITP Hurricane's
Sedona Mudder InLaws 30's
2 inch lift
24 inch light bar
2 cube lights
6 inch rear light bar
Wetsounds stealth 10 soundbar
BlueSea Fuseblock
2012 Polaris Rzr 800 all black
2005 Honda Rincon gone but not forgotten