Caddman new version keeping all FI control components

[ga1990]

I know everyone does the Caddman intake, and I really like the "new" version of it. The thing I didn't like was eliminating your idle air control valves and air intake temp sensor...it seems like you're taking a step backwards as far as technology goes. So here's what I did. I relocated the control valves up top and was able to keep everything setup basically just the same as the stock air box. I was also able to do it without cutting any wires, hoses, crossover tube, ect, etc so it could be easily put back to stock. I just got it done this afternoon, I'm still waiting on my new map from Fuel Moto, but so far it starts up just as easy and idles just as good as it did with the stock air box. Check out my pics:

Here's where I relocated the valves...I did have to make a bracket for the rear one:


Here's a couple photos of the intake i made out of 1/8" aluminum:



And here's the final product:

[Texrider]

You can't eliminate the temp sensor. If you do the FI light will stay on and it wouldn't run like its supposed to. The other stuff doesn't have to go but can eliminate some decel pop if you have any.

[audionutmike]

Very, very nice! I thought the same thing as far the idle air valves go, I didn't want to take a step back either but didn't know what else to do. Do you have a good pic of the bracket you made? I like where you put your temp sensor, I didn't remove the crossover tube so I had to place mine done on the lower right, but once I get the "nerve" up to get rid of it that's where it's going.


Great job

[woodjust4u]

Very Nice job! I thought about doing that but I went for the simple conversion Nice bike! looks like mine when I had the badges on it..Tom

[ga1990]

Sorry, I don't have any close up pics of the bracket...you can see it in that first pic. It's very simple though. I have a friend with a tig welder, so i had him weld it up out of the 1/8" aluminum i was using, but you could easily just make one out of thinner steel and bend it. On the part of if that you can't see, it's just a flat piect with two holes in it and I just used a zip tie to attach the control valve to it. As far as getting the crossover tube out, you can cut it like everyone else or just take the 4 bolts out of the intake manifold and everything lifts up. It still doesn't come out easy, but eventually I was able to wiggle it out the left side.

[audionutmike]

What I'm afraid of with the crossover tube is that with my luck, as soon as I remove it, I'll have an issue that will require taking it to the dealer and they'll say the warranty is void.....Thanks for the extra info on the bracket.
Once again, great work!

[DreamStreak]

Looks good, I like it better than the caddman.

[troop]

Much better looking than the standard 9" Caddman filter set-up.

[TJ's 02meanie]

Sweet addition to a great mod. Thanks.

[streak07]

I'm intrigued. I may have to attempt this myself. The one thing I've hated about the thunder mod is the need to use the fast idle knob.

[streak07]

OK, so question. On the idle solenoids whats the purpose of the upper hole popping out of the top? Does that need to be inside the intake area for best effectiveness or can it be mounted on the back side somewhere with no running issues?

In case anyone forgot what the stockl setup looks like, ignore the yellow arrows.

[ga1990]

Ok...those upper holes that are open are to draw in fresh filtered air, that's why they are mounted inside the stock air cleaner assembly....so on mine, I have hoses attached to the upper ports and ran the hoses to my new intake (that's the two smaller hoses you see coming through). That way the control valves are still getting clean air and you can mount them whereever you want.

[streak07]

OK, I was wondering what that extra set of hoses was. I'm gonna see if theres room to drill out the stock solenoid brackets and mount them inside the air cleaner assembly. That'll save me that step, if not I can always mount them on the back side. Looks like an extra weekend project.

[ga1990]

Are you using the same type of aircleaner that I did? Becuase if so, there's no way they will fit inside of it. My original plan was to mount them directly behind it and still use hoses, but I couldn't even figure out a way to get them to fit behind the new air cleaner, that's why i mounted them up top. This way you dont' see them at all and there was plenty of room for them, it was actually very easy to put them where i did.

[streak07]

No I've got the thunder one so its just the outer round filter. No center filter portion to get in the way. I just need to pop off the cover and see if there's room. I'm thinking there is but I won't get around to it until tomorrow probably.