This is a how to for those that are interested in doing this mod on 04 onwards bikes, i have done it on my track bike to allow more air and smoother air flow into the airbox, these bikes need as much as you can get in there, there will be some small gains regarding power, just don't ask me how much!!
First remove front fairing sections to get access to the intake housing
the removed intake
split the intake taking note of all screws and fitting locations, the brass looking thing at the top of the pic is the flapper valve
remove all the raised sections using whatever tools you have to do the best job, i used a Dremel and a nice sharp wood chisel
clean everything so you have no edges, rub down with fine sandpaper if need be, you don't want sharp edges or anything that will cause more turbulence, so get it clean and smooth
fill the flapper valve recess with silicone and smooth to give a nice flat surface, also build up silicone to block of the unused chamber as can be seen at the top of the picture
do the same on the other side with silicone
so when you put the two faces together you have the chamber blocked with a nice smooth surface
looking through the smoothed intake
the view of the flapper valve recess from outside the intake
finally put it all back together, not to forget putting the sensor back in the intake
A bit of a fiddly job, but should not be to difficult, hope this helps some of you in the quest for more power, and all at no cost, but watch your digits with all those sharp tools now :thumbup
First remove front fairing sections to get access to the intake housing
the removed intake
split the intake taking note of all screws and fitting locations, the brass looking thing at the top of the pic is the flapper valve
remove all the raised sections using whatever tools you have to do the best job, i used a Dremel and a nice sharp wood chisel
clean everything so you have no edges, rub down with fine sandpaper if need be, you don't want sharp edges or anything that will cause more turbulence, so get it clean and smooth
fill the flapper valve recess with silicone and smooth to give a nice flat surface, also build up silicone to block of the unused chamber as can be seen at the top of the picture
do the same on the other side with silicone
so when you put the two faces together you have the chamber blocked with a nice smooth surface
looking through the smoothed intake
the view of the flapper valve recess from outside the intake
finally put it all back together, not to forget putting the sensor back in the intake
A bit of a fiddly job, but should not be to difficult, hope this helps some of you in the quest for more power, and all at no cost, but watch your digits with all those sharp tools now :thumbup
