Motorcycle Club » Star 1100 Classic & Custom

Air Box

5 posts from 3 voices
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  1. Welter
    #

    Hi,
    I have been thinking about drilling my air box. I have already done a stage three mod on my stock exhaust. Will rejetting be needed ? Bike is a 2008 1100.
    Mike

  2. bkman
    #

    If you've drilled your exhaust and removed baffles, and now you want to open up the intake, then you will probably need to re-jet. The trouble is, I don't know what to tell you in terms of what jets to use. Since you are doing something "outside the box", you should plan on having the carbs off more than once but I am sure you can get it to work with time and patience. Just watch your plugs and listen very carefully to your exhaust to make sure you are not too lean.

    I would plan on at least increasing the pilot jets a size or two and the mains will probably have to go up a size or two as well, but you might just be able to raise the needles a little bit by removing the spacer and replacing with a couple of very small flat washers. The thing is, if you are not buying a kit, you have to experiment to find the sweet spot. That is where the patience and time investment comes in - what you save in money you spend in time.

    My only question is, when you say "drill the air box", I am curious how you intend to do this and maintain filtered air. It may be that there is some mod out there that I haven't heard about (I researched a lot of them before I did mine). If so, please elaborate so others might benefit from your knowledge (or at least be able to help you more).

  3. Welter
    #

    Hi,
    Thanks for the reply. I kinda thought I would have to rejet. The mod is very simple. You drill a pattern of holes in the housing on the front side of the stock air filter. You still get filtered air. It just lets more air flow through the filter. I think it takes about 30 or forty 1/8 " holes on the front side of the stock filter housing just in the black plastic. If I can find the info I'll post a link.
    Mike

  4. bkman
    #

    Okay, I get it. I never heard of that mod before, and I wonder how much it actually opens up the intake. It looked to me (when I took mine apart to do the Maxair kit) that the OEM filter and plumbing were the most restrictive part of the whole setup, but I don't know. I would love to see a photo of this.

    If you don't increase air flow too much, you might get away with it (without touching the jets) but be careful, and watch your plugs carefully. If it is too lean, you can destroy internal engine components.

  5. LiddleBen
    #

    I have seen these air filter mods. One guy said the drilled 72 holes in his. I took the other route.I realize that mods aint cheap and nobody is made of money these days. I bought a new Open aftermarket breather for my bike from Thunder mfg. I also purchased a stage 3 jet kit from them. then I took my bike to a dealer which has a Dyno and really good carb guy and 300.00 later I had a seriously better running bike. If you do the jet thing yourself plan on pulling the carbs off and changing the mains 2 or 3 times before you get it right. I would start with stage 2 jet kit. for now. I might add that I have had my bike gone through and 10 to 1 pistons,PCS x cams and valve springs etc. added now. Once you get to seekin more power you may find that Horsepower is addictive. I started with doit yourself mods and could not stop with these.

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