[2015 Z Force 800 53/Trail EPS]

                                                                                        Intake tube change-out.

While I was working on the CV intake system I had a chance to take a second look at the intake tube and although I installed a 3" intake on the end of that tube, the tube leading into it was much smaller





This works out to about 1.5". The manual says the throttle body is a 48mm which works out to 1.88". Ok, so..this should make restriction at some point and put a vacuum on the airbox. To test this I rigged a vacuum gauge on a long hose to the water drain port on the box and ran it up to the passenger seat so I could see it. Started it and gunned it. The needle only quivered a little at first then above ¾ throttle it pulled about  ½" of vacuum. Well that's not very much so I took it to the road in front of my house, put it in low and nailed it. This time it built up slightly over 1" of vacuum. Still not excessive but...you know me... can't leave well enough alone. So....

Coming off the airbox the boot is slightly over 2.5" and the OE tube makes a 70 degree bend. All I need to have is a 2.5" tube that I can oval like the OE tube and a 3" to 2.5" rubber 90, a new 3" joiner and some clamps to rid myself of this restriction. Bought these items:

http://www.ebay.com/itm/200650531642?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.com/itm/330580007204?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.com/itm/311652110458?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Custom cut to fit my application then ovaled  the tube and installed using better clamps.





Still have my large oiled gauze filter on the outside with the 3" intake.



Tested it again after reassembly and no vacuum build up at all..not even a quiver on the needle. And it did seem to be a little.. "perkier". Might be my imagination though...lol 

This was probably completely unnecessary... but not hard to do and it offers piece of mind that this will not be any reason to run out of power near the top of some sand dunes . 


 

Beautiful work

[2015 Z Force 800 53/Trail EPS]

Yeah the polished aluminum looks good...to bad no one can see it...lol

Nice and clean

MWKAW,
What is the size of your pipe that goes to bed?  Outside Dia?  Also what filter are you using to make it fit together right?

thanks

Rob

[2015 Z Force 800 53/Trail EPS]

MWKAW,
What is the size of your pipe that goes to bed?  Outside Dia?  Also what filter are you using to make it fit together right?

thanks

Rob

It's 3" through the bed plastic so I used a 2.5" to 3" 90 at the top, then cut down one of these 3" sleeves:

https://www.amazon.com/gp/product/B0089DZQJA/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

There is a clamp you can see on the inside that not only clamps that sleeve to the 90, but also holds some 90 degree legs that holds it on both sides...a close look you can see a couple of them. Then for a filter I have several with 3" openings that just clamps on the end. The one you see is my big one. Its a dry-type cotton but I do oil it. Its this one with a special order Outerwears water resistant prefilter.:

https://www.amazon.com/gp/product/B00MC64AZ6/ref=oh_aui_detailpage_o09_s00?ie=UTF8&psc=1

My CVT has one like it except a bit smaller and I think I will get another one like it because...the big one is so big...I have to take my box out to get it off. The one for the CVT is plenty large enough for the engine. It's this one...with a prefilter as well:

http://www.ebay.com/itm/4-6-W-COLD-SHORT-RAM-INTAKE-ROUND-CONE-BLACK-AIR-FILTER-3-3-5-REDUCER-ADAPTER-/151384042439?hash=item233f312bc7

Remember too that I also have an oversized two stage Unifilter in the airbox as well. A bit tight...but also zero restriction...or worries with it. It really never gets dirty with the one on the outside. It's this one:

https://www.amazon.com/gp/product/B00A3HLF4A/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

And this is what that big-puppy looks like in the box:

This was the first thing I planned to do to the intake get rid of the flat ass intake tube. I was thinking of just keeping it on the pass side and going straight up with it and snorkeling it there.

[2015 Z Force 800 53/Trail EPS]

This was the first thing I planned to do to the intake get rid of the flat ass intake tube. I was thinking of just keeping it on the pass side and going straight up with it and snorkeling it there.

Nothing wrong with that. Getting it out of that hot, dusty area is always a good step-1. In all honesty though that 2.5" didn't make any noticeable power gains...but..now when I put my vacuum gage on the airbox, it doesn't even quiver, its on zero no matter what the RPMs. I did have to ovel that tube slightly to fit too.

Very cool set up.  Couple questions.

- the tube from the airbox is factory and is 2.5" in diameter?
- that tube starts off round and then you flattened it to make it oval?

Thanks!

[2015 Z Force 800 53/Trail EPS]

Very cool set up.  Couple questions.

- the tube from the airbox is factory and is 2.5" in diameter?
- that tube starts off round and then you flattened it to make it oval?

Thanks!

The boot off the airbox is metric but 2.5" fits it fine. It is actually oval slightly to fit the OE pipe which has to be to fit behind the plastics without deflecting it. I think I have a pic of the end of the OE pipe somewhere. Yeah..here you go:

Excellent!  Thank you.  I think that's a great mod.  I probably won't do the pass-thru to the bed, but would love to put a foam filter on the end of that, and then use an outerwear. 

                                                                                        Intake tube change-out.

While I was working on the CV intake system I had a chance to take a second look at the intake tube and although I installed a 3" intake on the end of that tube, the tube leading into it was much smaller





This works out to about 1.5". The manual says the throttle body is a 48mm which works out to 1.88". Ok, so..this should make restriction at some point and put a vacuum on the airbox. To test this I rigged a vacuum gauge on a long hose to the water drain port on the box and ran it up to the passenger seat so I could see it. Started it and gunned it. The needle only quivered a little at first then above ¾ throttle it pulled about  ½" of vacuum. Well that's not very much so I took it to the road in front of my house, put it in low and nailed it. This time it built up slightly over 1" of vacuum. Still not excessive but...you know me... can't leave well enough alone. So....

Coming off the airbox the boot is slightly over 2.5" and the OE tube makes a 70 degree bend. All I need to have is a 2.5" tube that I can oval like the OE tube and a 3" to 2.5" rubber 90, a new 3" joiner and some clamps to rid myself of this restriction. Bought these items:

http://www.ebay.com/itm/200650531642?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.com/itm/330580007204?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.com/itm/311652110458?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Custom cut to fit my application then ovaled  the tube and installed using better clamps.





Still have my large oiled gauze filter on the outside with the 3" intake.



Tested it again after reassembly and no vacuum build up at all..not even a quiver on the needle. And it did seem to be a little.. "perkier". Might be my imagination though...lol 

This was probably completely unnecessary... but not hard to do and it offers piece of mind that this will not be any reason to run out of power near the top of some sand dunes . 


are you still running this air filter tube set-up,and if so how is it working out?

[2015 Z Force 800 53/Trail EPS]

                                                                                        Intake tube change-out.

While I was working on the CV intake system I had a chance to take a second look at the intake tube and although I installed a 3" intake on the end of that tube, the tube leading into it was much smaller





This works out to about 1.5". The manual says the throttle body is a 48mm which works out to 1.88". Ok, so..this should make restriction at some point and put a vacuum on the airbox. To test this I rigged a vacuum gauge on a long hose to the water drain port on the box and ran it up to the passenger seat so I could see it. Started it and gunned it. The needle only quivered a little at first then above ¾ throttle it pulled about  ½" of vacuum. Well that's not very much so I took it to the road in front of my house, put it in low and nailed it. This time it built up slightly over 1" of vacuum. Still not excessive but...you know me... can't leave well enough alone. So....

Coming off the airbox the boot is slightly over 2.5" and the OE tube makes a 70 degree bend. All I need to have is a 2.5" tube that I can oval like the OE tube and a 3" to 2.5" rubber 90, a new 3" joiner and some clamps to rid myself of this restriction. Bought these items:

http://www.ebay.com/itm/200650531642?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.com/itm/330580007204?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

http://www.ebay.com/itm/311652110458?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Custom cut to fit my application then ovaled  the tube and installed using better clamps.





Still have my large oiled gauze filter on the outside with the 3" intake.



Tested it again after reassembly and no vacuum build up at all..not even a quiver on the needle. And it did seem to be a little.. "perkier". Might be my imagination though...lol 

This was probably completely unnecessary... but not hard to do and it offers piece of mind that this will not be any reason to run out of power near the top of some sand dunes . 

are you still running this air filter tube set-up,and if so how is it working out?

Still running the 2.5" tube to 3" but have re-routed it to the right(passenger-side)bed corner for the snorkel/stack setup. Working great.

Old post, but what length 2.5" tube you use to oval out? the links are dead

[2015 Z Force 800 53/Trail EPS]

Old post, but what length 2.5" tube you use to oval out? the links are dead

Very old thread. Haven't had it this way for a very long time but I remember buying one with a bend that had the straight part well long enough to make the two points and just cut it. After fitting it I ovaled it. I changed it because everywhere I ride is so dusty, even coming out back there the filters were completely packed before the end of any ride. Went to stacks with in-line filters. Helped some but still couldn't finish some rides without having to stop and clear filters. Bridged the two and added a large Donaldson prefilter/particle separator to get me by until I could get my S&B..but it's worked so well I still use it.

So I first went from this threads setup to this:




Now it's like this until I get the S&B on:





This mock-up kinda shows what it will look like with the S&B: