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Grumpy mod done w/pics

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36K views 43 replies 26 participants last post by  tbg120  
#1 · (Edited)
Just did the grumpy mod, hopes this helps because I don't want to have to spend $39 every couple of trips, hell that's 2 30 packs of beer.:rofl3::rofl3: Opening is cut 6 inches wide and 6.25 inches tall. Web site won't let me load pics so I will try a different way.
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#6 ·
K&N P# 33-2008-1 I don't expect a noise isssue since I have a PRP bench seat between it and me, just remember to adjust clearance between seat and the filter if you have a rear bench. When I first put the seat in it made a perfect seal on the filter.
 
#7 ·
It's not loud at all. I was using paper filter but went to the K&N. You can pull it out and tap out the dirt and good to go. At the end of the ride just rinse with water and let dry. I can make 3 to 4 rides before checking the stock filter, which has a Outerwear on it. Also no oil on the K&N filter.
 
#11 ·
I wouldn't want to give a dimension from the bottom since the assembly of the air box and foward panel could vary considerably possibly causing you to cut the bottom of the air box so the best thing would be to reach under the panel to find the bottom of the air box and base your measurements off of that and start a bit higher than that. The filter comes with a seal which is very close to the the dimensions of the filter and I used it as a template for the hole, this made the hole smaller than it will finally be but it is a bunch easier to enlarge the opening a bit at a time than try to figure out a way to make it smaller so start at "your" base line, mark a center line and cut to make your filter fit snugly. Hope this helps.
 
#10 ·
I did away with my setup after I put a bench seat in. It was restricktive and was to loud (to much belt wine). I put a piece of rubber back over the hole I cut to get it back to factory but I added a snorkel going directly into the box from the top and put a filter on that so it pulls air from the snorkel and factory air inlet. The cvt and motor need alot of air and I just didnt think they would get that much air with that setup and a bench seat plus the filter got dirty quick which retricted that much more.
 
#12 ·
Don, just wanted to say thanks for posting these pics and info. I got mine done today and this thread made it so easy. I used a dremil to cut out the opening. Ordered the k&n filter from advance auto yesterday and it arrived this morning. 29.95. Thanks a bunch
 
#13 · (Edited)
You are welcome. I made a small improvement after the install since the noise was a bit more with the mod. I fabed a scoop out of sheet metal to go over the filter and the pick up is more like the factory set up drawing air from below and this also keeps the seat from touching the filter because at the end of every ride I could see the imprint of the filter on the back of my seat. This mod could also offer protection from elbows, gear or what ever making contact.
 
#15 ·
Scuba,

One quick question... You used black foam in a can at the bottom of the filter hole. Did you go all the way around it or did you make a mistake and use the foam for just the bottom edge?


I ask because obviously if the hole is the right size, it should fit without any foam.


Just checking.

Thanks,

Mark
 
#16 ·
I have a similar set up on mine. Straightline performance has a kit called big air. It incorporates drilling 5 2" holes and then is covered by FrogSkin. Frog skin is the silk material they use over snowmobile intakes that's allows air but no dirt or snow. I had my air filter and clutch housing plug up with snow dust about a year ago. We've done this and haven't been happier. it also increases the intake pipe size to the air filter.


2008-2012 Polaris Ranger 800 RZR Big Air Intake (excludes XP) « Straightline Performance
 
#17 ·
You want to increase mileage between filter changes? Two things don't follow so close in a group and put a lady's knee high stocking over your stock air filter.I can attest that this works well 12,000 miles on buggy 99% dezert riding and have never had dirt in the throttle body.
 
#20 ·
Pic 1, Here is the Fram I use, still under 6 bucks at Wally world.
Fram ca3916

Pic 2, The picture of the stock air filter in the air box has been in the machine for a year.

Pic 3, The paper Fram can be tapped out to reuse, but why reuse it when they cost about five bucks.

Pic 4, The picture of the two filters are a new one on the left and the one I just removed after a year on the right. You can see discoloration from oil vapor from the crank case vent.

Pic 5, Is the old filter.
 

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#26 ·
When I pulled the bed I found air was leaking at the top of the air box so I added some automotive foam weather stripping and now the box is well sealed and all air flow is through the K&N filter.
 
#28 ·
Newbie here and trying to learn and figure this out,, ...So from the factory, is the only place the air box is supposed to pull air in, is at the front, between the seats, at below the lip where you sealed with the foam?
Also then, from this air-box the intake air goes to the factory filter then to the engine?
Is that right?
If all that is true, what is the snorkel in the back above the engine? What does it do?
Thanks
 
#30 ·
......If all that is true, what is the snorkel in the back above the engine? What does it do?
Thanks
Actually, that's not a snorkel, it's the exhaust-tube from the CVT case. There are two tubes that come into the bottom of the Intake-Plenum box; one goes to the air-filter canister and the other is the intake-tube for the CVT case. Hope this helps.........

Cheers
 
#29 ·
An alternative to the cartridge-filter is to install a Holt Racing intake grill, backed by a flat layer of OuterWear filter material, which is what I've done. The OuterWear material filters better than a Fram or a K&N, IMO, and it tends to be self-cleaning, since the normal "pulsing" of the intake tract keeps the dust/debris shaken-off of the OuterWear material. The flat material has no pleats to "trap" anything, so gravity does the rest. And you don't ever need to replace it, just wash it now and then in dish-washing soap (I've washed mine once in the past year). Just a FWIW.............

Cheers