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Fitting instructions for Motohooligan airbox

73 posts · Started by bic_bicknell · 01 Jan 2010

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Post 1 by bic_bicknell,

#1
Whilst I just fitted a Motobox and removed the whole SAS system I took photos and was intending to put together a comprehensive set of fitting instructions so that Aaron can send out a pdf document to future customers.

As a document it really needs an introduction page but I'm not really qualified to author what needs to be said so is there anyone out there who could supply some, correct, information about a few things which could go at the front?

I spent a long, long time reading through all the threads on this before I felt I even knew half of what I wanted to know before committing to spending the money and time to do this conversion and it would have made it a lot easier if I could have read an abbreviated version of everything I needed to know. Help Aaron sell more airboxes as well I think. It could have links in it to some of the better threads on the subjects.

The main things I, (personally), wanted to know include the following:

BENEFITS. What are the real, proven advantages of the Motobox. I want to see a dyno chart really comparing standard with conversion. Has anyone got one? I've seen some on threads.

RECOMMENDATIONS. Some testimonials from happy Motobox customers. I know there are many.

PC111 / Tuneboy information. Is it totally necessary to fit one of these with the Motobox? If so advice on maps, custom maps etc. If not what's the best way to set up a standard bike to suit?

EXHAUSTS. What's the advice about matching the airbox to different exhausts?

SAS system. (Whew, it's been the longest learning curve for me to absorb the info about this, what it does, whether you need it, whether there are performance gains to be made without it or not). New owners have to go through this every time - isn't there a definitive answer out there?!!

O2 sensors. Same as above.

If anyone has any views on any of the above or thinks there could be other topics that should be covered then drop them in here and I will try and sort them out into something readable and informative.

Here's a sample page of how I thought the instructions could look:

Post 2 by ktmguy,

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Post 3 by Motohooligan,

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Post 4 by Plipton,

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Post 5 by bic_bicknell,

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Nearly done.

I just got an e mail from Aaron a few days ago and he just wanted me to change the disclaimer slightly and put in the correct weight of the Motobox.

I'll try and do it tomorrow and send it over to you.

What do you think the best way to let people know about it.? Probably a post from you or Aaron direct?

Post 6 by Plipton,

#6
I'll make it a sticky in the 'how to do it' section

Post 7 by Motohooligan,

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Post 8 by Plipton,

#8
. Thanks to Bic and Aaron for doing this.

Post 9 by Superdan,

#9
Nice work

Post 10 by Twisted Jester,

#10
Really nice work Bic, well done.

Post 11 by ktmguy,

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Post 12 by TheJoker,

#12
WOW that's a nice PDF. Nicely done! Very nice! Can't wait to put it to use now!
My only OCDish pet-hate is the term PC111, as it's not onehundredandeleven, but three, and hence PC3 or PCIII where III is the roman numerals for three. I'll get my coat.

Post 13 by Plipton,

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Post 19 by FlyingScotsman,

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Post 20 by scotsduke,

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Post 21 by FlyingScotsman,

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Post 22 by bic_bicknell,

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Post 23 by FlyingScotsman,

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Post 24 by ktmguy,

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Post 25 by FlyingScotsman,

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Post 26 by TheJoker,

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Post 27 by bic_bicknell,

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Post 28 by bic_bicknell,

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Post 29 by Plipton,

#29
poor me,my closest ktm dealer is on hongkong and seems impossible to do it.other solution maybe is buying a pc3.

Post 30 by TheJoker,

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Post 31 by Anata,

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Post 32 by Plipton,

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Post 33 by harvester,

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Post 34 by Anata,

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Post 35 by Twisted Jester,

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Post 36 by Plipton,

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Post 37 by Davo-Singapore,

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Post 38 by DUKEHag,

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Post 39 by mets70,

#39
Got mine installed last weekend and I'm a happy camper. Thanks Bic for the instructions - worked a treat. My only problem here was getting hold of the Loctite 271 for the flies screws that Aaron specified - but got that sorted in the end.

Post 40 by bic_bicknell,

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Post 41 by mets70,

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Post 42 by bic_bicknell,

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Post 43 by mets70,

#43
Cheers Bic, my bike is loud enough now with the Akras and the baffles removed, does the Motobox make that much difference?

Post 44 by samba,

#44
Oh yes. Wait and see. Induction roar is louder than a ZXR Kawasaki. There's a resonant frequency it hits at a certain revs that makes your ears bleed. It's all good though.

Post 45 by mets70,

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Post 46 by Plipton,

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Post 47 by bic_bicknell,

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Post 48 by Plipton,

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Post 49 by mets70,

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Thanks again guys. For the record the dyno guy doesn't sell either I was just wondering which one I should go with.

Post 50 by Plipton,

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Post 51 by SUPER DUPER DUKE DUDE,

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Post 53 by SUPER DUPER DUKE DUDE,

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Post 54 by cdv478,

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Thanks for writing this guide. It made the installation straightforward and enjoyable, and they look very well written.

Post 55 by bic_bicknell,

#55
cdv478,

You are welcome. Reason I did this guide for Aaron was exactly so that guys like you would have an easy time getting the most out of a bit of kit I was well impressed with. Plus I grew up with a fascination of Haynes manuals and I always wanted to do a photo-story in the same style! Plus - I think I must have had a bit too much time on my hands at the time

I'd do some more for fun but there's not really that much you need to do to a Superduke that isn't real easy.

Post 56 by Twisted Jester,

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Post 57 by bic_bicknell,

#57
TJ. You are right. The last 10 days have been a routine of feeding twins every three hours round the clock. It takes about an hour to feed them both, change their nappies, wind them and get them settled. Then it's all the jobs that need doing - washing clothes, bibs, bedsheets, muslin towels. Washing and sterilising bottles, making up formula milk for top-ups, Amy expressing more milk for bottle feeds in the night. Then it's thinking about the next meal and cooking enough so that maybe you can get two or three meals out of it - and then cleaning up and tidying and keeping on top of the general chaos. And also we have our 18 month old, Esme, who needs almost constant attention as she's getting into trouble, climbing the walls and destroying everything she contacts, (all in the best possible taste of course).

All this done in an almost catatonic state of tiredness and fugginess.

But I still have time to sit and log on here while I grab 5 minutes in between all that. It keeps me sane. And I'm actually am on here more than normal the last week or so - it gives me another purpose in life, No more manuals though! But I am going to try and make a carbon numberplate and post the results in the next few days. There is always time to squeeze in these necessary tasks.

Post 58 by samba,

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Post 59 by Twisted Jester,

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Post 60 by Davey Sprocket,

#60
WOW.. This thing looks amazing... I'm sure Arron will be happy to send me a free sample to us here in Darkest Africa... Sure it will increase his sales... SHAMEFUL begging i know.. but at this point i'd give my grandmother for one... if you interested she's 84... and still got alot of life in her!! LOL

Post 61 by Plipton,

#61
Nah, you want a

Post 62 by MRK-01,

#62
Finally got some time this weekend to put the motobox on.

followed the instructions form here, perfect..!! Even noted that its a pain in the ass to get the front SAS bolts out..!! hahaa..!!

All done, even swapped out the 2nd' flies with the motoflies. My 07SD is even more an animal than it was before..!! DAMN/..!! Dont know why I didnt do this earlier..!! But runs like an absolute dream, other than a sticking throttle every now an then, its brilliant..!!

Post 63 by MrZ32,

#63
I'm still waiting for my MH kit to be delivered Aaron was quick to ship but custom clearance takes a while.

What's the difference between the standard 2'nd flies and the motohooligan ones ?

Post 64 by MRK-01,

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Post 65 by bic_bicknell,

#65
not too sure what it does for performance gains as I did a few changes at once.

I did the motobox, SAS block and moto flies (which are oval in comparison to the original round ones). And I loaded up a new TuneECU map
"file08_SD_james_map_for_grim_and_motobox_will_run_motobox_as_it_is_rich_enough.hex" with only the 2nd throttle devices checked.

So I cannot see exactly what the moto flies have done exactly, just know I gotta bucket more power..!! The ride to work this morning was a ball..!!

What are the 2ndary flies for exactly..? If you take them out completely what will this stop..?

Post 66 by MrZ32,

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Post 67 by MrZ32,

#67
The standard secondary flies are round and completely block off the throttle bodies when shut. The MH versions are slightly oval so that even when shut allow air through. It has been widely debated about the benefits of fitting these or running with standard or completely removing them but I have never seen any dyno runs after only these mods to know if there is any tangible benefit. Most people do it as part of more mods at the same time. I know Colonel Klink fitted the secondary flies as a separate exercise. He said, I think, that his throttle was smoother as a result but I can't honestly say I noticed any difference - it's too subtle. But I also had my fitted a full system exhaust and re-dynod at the same time so the map was adjusted to compensate for any change anyway.

Post 68 by scamb66,

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Post 69 by Sabre,

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Post 70 by preey,

#70
not a question about fitting but how long does it take to be shipped to the uk i only ordered a set of butterflies & the resister

Your item was processed through and left our DENVER, CO 80266 facility on May 09, 2011 at 9:23 pm.
The item is currently in transit to the destination. Information, if available, is updated periodically throughout the day. Please check again later.

states never changers

Post 71 by preey,

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Post 72 by Twisted Jester,

#72
ok thanks ive had the motobox 6mths but never fitted it in the winter i just got a new sdr so its going on that so im not wanting to cut the sas plug of so ive also ordered one of the plugs along with the butterflies so should be with me soon i hope

Post 73 by preey,

#73
I think the Joker posted up once on how to check your status online with royal mail as undoubtably it's probably sitting in customs

I usually plan for at least 3 weeks from the US
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