Another Pod Filter Mod ???
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Member
Fuoco 500
Joined: 30 May 2020
Posts: 13
Location: Cabramatta, New South Wales
Wed Aug 05, 2020 3:05 am quote
Hey Fellas

Rolo here from Australia. I know this bike is heaps old and barely anyone talks about it anymore, meanwhile, i have been tinkering on it for the past couple of months.

Anyway, here is my Pod filter mod for your perusal.
I quite like this look, gives it sort of like a second exhaust look...
I have used the following so far:

2 Inch 45 bend Silicone (Ended up cutting it up to use as a straight Joiner)
4 Inch to 2.5 Inch Reducer silicone
K&N RC 2330 Filter
2 inch 45 Bend aluminum Pipe
4 inch Straight pipe (250mm)
Sound Insulator (Wrapped the inside of the large pipe)
Buncha' Hose Clamps

All up costed me about $140 AUD (So far)
Its not too loud, but the large pipe gives it a low rumbly growling noise, very mean.

I Havent finished yet, i still need to fashion a bracket to stop it wobbling around, and maybe make some sort of baffle thing on the end. That opening is too big and ugly. And then i need to work on that crank case breather. Thinking of slapping on an oil separator and then joining it to the clean air side of the intake.

I will post the end product when i have time to finish it this weekend.
This forum has been a great inspiration to me ! Thank you !

Heres some eye candy !

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Sound Insulator Wrapped

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Heaps of Clearance for bouncing

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I Removed the High beams and replaced them with low angle Fog beams and DRL Halo combos.

Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 328
Location: United Kingdom.
Wed Aug 05, 2020 11:54 pm quote
I like the twin silencer look , pity it's not same both sides.
Molto Verboso
Kymco AK550
Joined: 09 Feb 2008
Posts: 1157
Location: UK
Thu Aug 06, 2020 12:05 am quote
I'm not sure how concerned you are about performance but if you want to retain or improve the original throttle response and acceleration you will probably need to experiment with different sizes of restrictor somewhere in the intake. With variator transmissions its very difficult to ride around any flat-spots in the acceleration phase, especially if you like to use full throttle.
Member
Fuoco 500
Joined: 30 May 2020
Posts: 13
Location: Cabramatta, New South Wales
Thu Aug 06, 2020 3:30 am quote
Thanks for the tip roadster

I've gone and purchased a few different sizes of PVC reducer (for the intake tip) to limit the inflow, and will experiment with them to see what feels best.

Meanwhile I purchased an air water/oil separator ($12) and slapped on a few air tool bits and bobs I had laying around resulting in this ! Now to stick this on the new airbox(pipe) ???

This will catch all the oil blowby and recirculate the crankcase air back into the intake. Same as the original airbox did.

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Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 328
Location: United Kingdom.
Thu Aug 06, 2020 2:52 pm quote
Rolo beware using that water seperator as i used exactly the same type when i changed to a ram-air foam filter as they rust badly on the steel fittings,i found out after only 1000mls. I ment to photo what i replaced it with but forgot will post a photo tomorrow.
Molto Verboso
Kymco AK550
Joined: 09 Feb 2008
Posts: 1157
Location: UK
Thu Aug 06, 2020 11:57 pm quote
As far as the breather is concerned I preferred to use a very large diameter open pipe directed upwards first then exiting at the rear of the scooter. Oil from the breather then drains back into the crankcase and very little comes out from the tube. Keeping an eye on this is a good way to monitor the health of the engine.
Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 328
Location: United Kingdom.
Fri Aug 07, 2020 12:10 am quote
roadster wrote:
As far as the breather is concerned I preferred to use a very large diameter open pipe directed upwards first then exiting at the rear of the scooter. Oil from the breather then drains back into the crankcase and very little comes out from the tube. Keeping an eye on this is a good way to monitor the health of the engine.
Which is what i have now done.
Member
Fuoco 500
Joined: 30 May 2020
Posts: 13
Location: Cabramatta, New South Wales
Fri Aug 07, 2020 12:29 am quote
roadster wrote:
As far as the breather is concerned I preferred to use a very large diameter open pipe directed upwards first then exiting at the rear of the scooter.
I did think of this too, however I wanted to keep it similar to the original setup, and with the oil catcher I will be able to see an extra detail on the function of the engine. I don't mind draining it, and at least I'll know how much I've lost.

It kind of looks cool anyway , the extra thing on there ☺️
3legsofman wrote:
Rolo beware using that water seperator
I saw your message too late, I have already installed it hehe. I believe mine is made of aluminum and stainless steel but I will see how it goes. There were other more expensive and better quality looking ones on the shelf but this was the cheapest one I picked so, we'll see how it goes.

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Hooked
2008 fuoco
Joined: 19 Jul 2015
Posts: 328
Location: United Kingdom.
Fri Aug 07, 2020 1:45 am quote
Check it with a magnet believe me it was VERY bad after only 1000mls my filter looked identical as yours about 3 on ebay, it's a pity i diden't take photos. Here is MK 2 version on my fuoco. Ram-air foam air filter and Ramair breather filter. I replaced the original breather pipe with a clear tube so i could see what was going on , notice there is no sign of any thing after a 300 mile ride which included some very high motorway speeds.

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Member
Fuoco 500
Joined: 30 May 2020
Posts: 13
Location: Cabramatta, New South Wales
Fri Aug 07, 2020 4:04 am quote
Finished !

I've decided on a 50mm inlet.

It sounds and feels just right.

I've been inspired by the legend of the fuzzy washer. His legacy lives on !

I've ordered some stainless M20 3mm washers.
Can't wait to try that !

And probably on my to do list is a HIT clutch as well.

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Here is the contraption

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Final product

Member
Fuoco 500
Joined: 30 May 2020
Posts: 13
Location: Cabramatta, New South Wales
Sat Aug 15, 2020 3:27 am quote
Results after 500km
So after about 500km of riding, I am definitely noticing an increase in fuel consumption. It's not much, I haven't done any measurements.

The bike does seem quite peppier and picks up quicker from a stop. Acceleration is definitely better than before. No much, but noticeable. Engine seems to be running hotter for longer as the cooler fan is kicking on more frequently now I would say twice as frequently. But temperature gauge is staying in the middle as normal.

I experienced some hard starting for the first two days. After realising I hadn't reset the ECU relearning, I did so and it now starts fine.

The blow by collector seems to be doing its job. Here is a pic.
Seems to be an emulsion of mostly water moisture and oil and whatever else If anyone knows if this is normal or not, let me know ! Thanks

So far... Seems good ? I will check the throttle body for any deposits maybe at 2000km

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Hooked
Piaggio MP3 500
Joined: 21 Nov 2017
Posts: 296
Location: Austin, TX
Mon Aug 17, 2020 11:50 am quote
Looks like mostly water to me. But the whole system seems upside-down to me. (Maybe it's the antipodean way of doing things.) Usually the condensate in these trap things is supposed to drain back into the crankcase through a tiny hole that bypasses the reed valve. But then again, its not good to put water into the crankcase, so your system might actually be better for the engine than stock. When everybody was experimenting with traps in the breather line, mostly the condensate was oil mist, and in extreme cases the oil level would go down dramatically over as little as 100 miles. But those were usually cracked pistons causing the problem.

I'd just empty the container often and ride.
Member
Fuoco 500
Joined: 30 May 2020
Posts: 13
Location: Cabramatta, New South Wales
Fri Aug 21, 2020 1:03 am quote
3legsofman wrote:
Rolo beware using that water seperator as i used exactly the same type when i changed to a ram-air foam filter as they rust badly on the steel fittings.
Mine really was aluminum and stainless, so far no rust. However the plastic cup has cracked in more places than one. I'm not sure why as I didn't do it up that tight, el cheapo anyway

I've gone and bought this more expensive looking one, hopefully this'll last longer. The drain valve comes normally open (push to close), so what I did was take the inner spring and placed it on the outside, now it is normally closed (push to drain).

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