how not to: cheap pod filter beer can mod

[zzay]

somehow I don't have any pics of the process, but I cut a beer can lengthwise and then around the circumference to yield two rectangular pieces of aluminum from one can. I then cut strips into the can so it would be easier to bend into a cone shape.



then I installed the can into the pod, pressing it neatly into the pod filter.

fast forward a few months, I finally get around to firing up my project for the first time. it runs... terribly. snappy response at idle, but bad stumble around 2.5k rpm under a load. I decided to put the airbox back on to see if the pods were causing it. this is what I found.



the thin aluminum strips weren't rigid enough to resist the vacuum and crumpled up. don't do this.

the bike now has the old airbox (which was in a fire and is held together by zip ties and duct tape) and is running great with a new K&N filter. great enough for me to realize now that the clutch is slipping. might be due to the fact that in my haste to test ride this beast I dumped some synthetic oil in that I had extra from my car...

thanks for reading

[DiverRay]

For the clutch, replace the oil and filter, but put 1/2 cup Seafoam or B-12 Chemtool into the crankcase first, and idle it for about 5 minutes with a fan blowing over the engine. This will help soften seals and clean gunk out of the engine.
Next, order a set of BARNETT clutch springs and install them. This will fix the 30 year old springs that are probably sprung.
Finally, ride and enjoy it!

[zzay]

For the clutch, replace the oil and filter, but put 1/2 cup Seafoam or B-12 Chemtool into the crankcase first, and idle it for about 5 minutes with a fan blowing over the engine. This will help soften seals and clean gunk out of the engine.
Next, order a set of BARNETT clutch springs and install them. This will fix the 30 year old springs that are probably sprung.
Finally, ride and enjoy it!

excellent, thanks for the info. are these the ones? https://www.amazon.com/Barnett-Clutc.../dp/B000LGW3CQ

[DiverRay]

Yes, those are the correct springs. Google Barnett and go to the barnett engineering web page to look up parts.

[madmax-im]

you know our hobby isnt cheap but damn it isnt that expensive either...some things are just worth paying for... you are brave to admit the mistake but what were you thinking???

[kboehringer]

Contact ANDREAS

which was in a fire and is held together by zip ties and duct tape

ZZAY,
Contact member "ANDREAS". Send him a private message asking about the air filter assy. you need. He has been providing parts to the guys here for years. His prices are EXTREMELY reasonable, and he stands behind the parts he provides. I've never had ANY issue working with him and he has gotten me out of trouble a couple times.

He is very likely the best deal you will ever get on a replacement.

Sincerely,
KURT

P.S. There is a HUGE rally planned for late next month. Not too bad a drive for you from the Augusta area. Check the Southeast section for XSSE Rally.

[madmax-im]

excellent, thanks for the info. are these the ones? https://www.amazon.com/Barnett-Clutc.../dp/B000LGW3CQ

those appear to be correct...I have bought from Powersport Superstore...they were slow to ship my parts but otherwise were okay..i just didnt agree that a week should go by between the time i ordered and paid and the time they actually shipped the item...sorry if I sounded harsh above ..Welcome to CH11...

[zzay]

those appear to be correct...I have bought from Powersport Superstore...they were slow to ship my parts but otherwise were okay..i just didnt agree that a week should go by between the time i ordered and paid and the time they actually shipped the item...sorry if I sounded harsh above ..Welcome to CH11...

no hard feelings

I ordered from them, eta is somewhere between this friday and next wednesday. hope I get a shipping notification soon.

the reason I'm being cheap is this bike is a POS and I didn't want to sink a lot of money into it right off the bat. it has too many issues to list. the previous owner kinda hacked things together to keep it running instead of fixing it properly so I plan to go through it one component at a time.

[kboehringer]

I plan to go through it one component at a time.

ZZay,
In my opinion, that is EXACTLY the way to go! Pick something screwed up, fix it correctly, then move on to the next item!

That bike looks good and a heck of a lot letter than my three did when I got them. Most of the big stuff is there!

KURT

[madmax-im]

no hard feelings

I ordered from them, eta is somewhere between this friday and next wednesday. hope I get a shipping notification soon.

the reason I'm being cheap is this bike is a POS and I didn't want to sink a lot of money into it right off the bat. it has too many issues to list. the previous owner kinda hacked things together to keep it running instead of fixing it properly so I plan to go through it one component at a time.

Of course theres always more to the story than initially meets the eye...Seeing the state of your bike...i can now appreciate your thought process a bit clearer...IMHO many ppl make the mistake of dealing with too many things all at once...so indeed as Kurt has said pick one item and fix it then move on to the next issue. You wouldnt believe how many new members come on here and think they know how to do it and they ignore sage advice... Good luck bringing this one back...and hopefully you'll make the rally at the end of Sept... BTW that seat has to go...its FUGLY!!! BTW BTW whats with the pink accents...former owner a girl?

[zzay]

ZZay,
In my opinion, that is EXACTLY the way to go! Pick something screwed up, fix it correctly, then move on to the next item!

That bike looks good and a heck of a lot letter than my three did when I got them. Most of the big stuff is there!

KURT

thanks, that actually makes me feel better about it. once I got it to fire up it really renewed my interest in the project.

Of course theres always more to the story than initially meets the eye...Seeing the state of your bike...i can now appreciate your thought process a bit clearer...IMHO many ppl make the mistake of dealing with too many things all at once...so indeed as Kurt has said pick one item and fix it then move on to the next issue. You wouldnt believe how many new members come on here and think they know how to do it and they ignore sage advice... Good luck bringing this one back...and hopefully you'll make the rally at the end of Sept... BTW that seat has to go...its FUGLY!!! BTW BTW whats with the pink accents...former owner a girl?

doubtful on making the rally unfortunately... work has me tied up for the foreseeable future. I agree on the seat, another thing on the list. the pink highlights are from my sweet pink canopy I got for cheap on craigslist, lol. it looked more like purple in the ad, I swear

[DiverRay]

Hey, you HAVE a fork brace on it, and it looks like a T-KAT! You also have a KIRKER exhaust, both VERY GOOD starts. I also see the T.C. fuse block, so that's three items off the list! It does look like you have most of what you need to get it reliable without spending any big bucks. Cosmetics are ALWAYS the costly part though.

[zzay]

just got my springs from powersport superstore.

ordered monday evening 8/15/16, shipped monday 8/22/16, received friday 8/26/16. they are kinda slow.

[madmax-im]

just got my springs from powersport superstore.

ordered monday evening 8/15/16, shipped monday 8/22/16, received friday 8/26/16. they are kinda slow.

yep...told ya...i wont recommend them..Len at XJbikes.com or "chacal" is they person i should have ordered my parts from... glad you finally got your stuff