Fog's Air box Mod - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 150 (permalink) Old 8-19-2007, 1:28 PM Thread Starter
fog
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Fog's Air box Mod

The stock EX jetting from the factory setting is extremely lean at Idle and low speed running. Then overly rich at high RPMs. This is due to the ridiculous EPA requirements and the rules for testing. The EPA test concentrate on the low end of the performance. So to get something approaching a reasonable overall performance the over rich high end jetting takes over a little sooner in the RPM range ,then reasoning that not many run full throttle for very long ,or couldn't tell the difference that a fat jetting up high makes .

The FOG Air box mod addresses this . By enriching the bottom and leaning out the top.

I have discovered a minor alteration (MOD) to the airbox that has proven value. In my never ending quest for an unfair advantage for my race bike. I was testing jetting on a Dyno one day. I discovered that the Air box was too restrictive and ran a vacuum that seemed too high. I made many tests to determine that 1 additional hole of 1" in diameter was Ideal. This hole is located in the rear facing end face of the left side airbox cover.
Further tuning proved that adjustment of the Pilot screws was all the Jetting that was required. Now I also used a KN filter, because I got 1 hour of free dyno time with the purchase.
My net result was: 53.9 HP or a improvement of almost 4 HP from stock (My stock was not necessarily optimum)..

OK here it is again:

Drill a 1 inch dia hole or multiple holes with a area of no more than .7854 square inches. Remember pi X R squared. In the rear end of the left side airbox cover. This location was chose to Hide the mod from prying eyes in the pits. I tested no other

Fit a new KN filter

Be sure your carb. Pilot jets are clear and the Sync. is good.

Then un plug the pilot screws and adjust them for the best results. I did it this way: Wack the throttle wide open and listen to the engine rev to about 8-9000 RPM adjust the pilot evenly about 1/4 turn each time till the smoothest acceleration is obtained.

Reset Idle to taste.

No you can not substitute any thing else for this MOD. You of course can do anything you want . just don't call it the FOG Mod.

The Factory has not adopted this mod in any way, regardless of how many holes or trumpets you count it has not been done, unless you have put a 1" hole in the end of the left side cover. it needs one.

Please do not add or attempt to alter this post, write your own.

Thanks FOG

I have to add this disclaimer: It is assumed your engine is in otherwise perfect condition. The FOG MOD is the last tuning you do. after valves ignition wires etc.

FOG
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post #2 of 150 (permalink) Old 3-14-2010, 5:56 PM
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Re: Fog's Air box Mod

Here is a picture of the common location of the hole that should be drilled into the left airbox cover:



Here is my personal setup as I intended to cover up holes if necessary to tune performance to my liking.
Four 1/2" holes are the same total area as one 1" hole, and it's the area (Pi x radius2)
:



And the location of the pilot screw caps which must be removed to get to the screw (picture is looking at the bottom of one of the carbs):


Here is a video of drilling out the pilot screw caps on the underside of the carbs
http://www.youtube.com/watch?v=mRUm6CcvqRA
post #3 of 150 (permalink) Old 4-13-2010, 9:42 PM
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Re: Fog's Air box Mod

This is certainly more clear than the other thread was... especially on the question of the trumpets and hole.

One question, are those pilot screw caps able to be pried off somehow or are they only drillable?

Thanks... hope this isn't considered 'altering' the post, if so, I'll delete it.

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post #4 of 150 (permalink) Old 4-13-2010, 9:47 PM
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Re: Fog's Air box Mod

There's no leverage to pry them off without making a hole somewhere. I drilled a hole upwards into the caps with a dremel (a drill wouldn't fit in that space to get the right angle), and then used a metal hook kind of tool to reach in and pry out the cap.
post #5 of 150 (permalink) Old 4-15-2010, 10:29 AM
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Re: Fog's Air box Mod

Is the engine much louder after this mod?
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post #6 of 150 (permalink) Old 4-15-2010, 10:46 AM
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Re: Fog's Air box Mod

No.
post #7 of 150 (permalink) Old 5-2-2010, 10:16 PM
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Re: Fog's Air box Mod

Quote:
Originally Posted by gbologna
Is the engine much louder after this mod?
I noticed a bit more intake noise than before, but it was so slight that it might have been my imagination.

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post #8 of 150 (permalink) Old 5-5-2010, 10:48 AM
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Re: Fog's Air box Mod

Quote:
Originally Posted by gbologna
Is the engine much louder after this mod?
Only until the mud and other debris from the rear tire fill up the hole

Poor planning on your part does not create an emergency situation on my part.
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post #9 of 150 (permalink) Old 6-18-2010, 9:50 AM
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Re: Fog's Air box Mod

Just a quick question. I have done the mod to my airbox and will be adjusting the screw later today. My question is in the above picture from Pogo, it was stated that four 1/2" holes are the same total area as one 1" hole. ? Wouldn't that be a total of 2". Four 1/4" holes would equal a 1" hole. Only asking because I put two 1/2" holes in my airbox.
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post #10 of 150 (permalink) Old 6-18-2010, 9:58 AM
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Re: Fog's Air box Mod

REally man....

the AREA of a circle is what?

pi * radius * radius

4 * radius/2 * radius/2 = radius * radius

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post #11 of 150 (permalink) Old 6-18-2010, 11:28 AM Thread Starter
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Re: Fog's Air box Mod

Come on guys 4th grade math Area of a Circle is calculated P(3.1416) X (multiplied by) Radius Squares (Miltilpied by it'self)

pi X r squared= A

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post #12 of 150 (permalink) Old 6-18-2010, 8:06 PM
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Re: Fog's Air box Mod

Heh, I had a feeling that picture was gonna screw someone up some day.
post #13 of 150 (permalink) Old 6-22-2010, 12:22 PM
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Re: Fog's Air box Mod

Quote:
Originally Posted by Pogo
Here is a picture of the common location of the hole that should be drilled into the left airbox cover:



Here is my personal setup as I intended to cover up holes if necessary to tune performance to my liking.
Four 1/2" holes are the same total area as one 1" hole, and it's the area (Pi x radius2)
:



And the location of the pilot screw caps which must be removed to get to the screw (picture is looking at the bottom of one of the carbs):
is this a 1st gen or 2nd gen?
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post #14 of 150 (permalink) Old 6-22-2010, 5:12 PM
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Re: Fog's Air box Mod

both
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post #15 of 150 (permalink) Old 6-22-2010, 5:24 PM
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Re: Fog's Air box Mod

Quote:
Originally Posted by AgentOrange
both
Yes. The airbox and carburetor systems are identical on all year ex500s, 1987-2009
post #16 of 150 (permalink) Old 7-3-2010, 3:52 PM
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Re: Fog's Air box Mod

Quote:
Originally Posted by FOG
Be sure your carb. Sync. is good.

Then un plug the pilot screws and adjust them for the best results. I did it this way: Wack the throttle wide open and listen to the engine rev to about 8-9000 RPM adjust the pilot evenly about 1/4 turn each time till the smoothest acceleration is obtained.
Im planning on doing this mod, my question is, right now i have my bike opened up well i wait for my replace stud for my cylinder cover to come in, and i plan to sync my carbs once it does and i close the cover back up, should i wait to do the mod till after i sync the carbs or should i go ahead drill the hole drop the filter now and then adjust the pilot screws after i sync carbs? basically would it be better to sync then run mod and would it just be easier to run mod first and fine tune everything after?
And for the caps over the pilots screws i was able to get it off with a normal drill while the carbs where still, basically drilled a hole across the cap and on the far side it went all the way through where i was then able to use a nail to pry it off, just took some patience and a steady hand, i really didnt feel like taking my carbs off :P
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post #17 of 150 (permalink) Old 7-3-2010, 4:57 PM
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Re: Fog's Air box Mod

Turn the screws to 2.5 and then sync. Tune screws identically afterward until the bike rides as you want it.
post #18 of 150 (permalink) Old 7-3-2010, 5:33 PM Thread Starter
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Re: Fog's Air box Mod

Quote:
Originally Posted by masse21
Quote:
Originally Posted by FOG
Be sure your carb. Sync. is good.

Then un plug the pilot screws and adjust them for the best results. I did it this way: Wack the throttle wide open and listen to the engine rev to about 8-9000 RPM adjust the pilot evenly about 1/4 turn each time till the smoothest acceleration is obtained.
Im planning on doing this mod, my question is, right now i have my bike opened up well i wait for my replace stud for my cylinder cover to come in, and i plan to sync my carbs once it does and i close the cover back up, should i wait to do the mod till after i sync the carbs or should i go ahead drill the hole drop the filter now and then adjust the pilot screws after i sync carbs? basically would it be better to sync then run mod and would it just be easier to run mod first and fine tune everything after?
And for the caps over the pilots screws i was able to get it off with a normal drill while the carbs where still, basically drilled a hole across the cap and on the far side it went all the way through where i was then able to use a nail to pry it off, just took some patience and a steady hand, i really didnt feel like taking my carbs off :P

Drill the hole , open the pilot screws. Fit the air filter you going to use the sync the carbs, the last thing you do is tune the pilot screws, after all else in in place as you plan to ride it.

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post #19 of 150 (permalink) Old 7-9-2010, 2:09 PM
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Re: Fog's Air box Mod

Let's say hypothetically someone drills holes in the RIGHT SIDE of the air box. Would this yield the same result or just label that person as a DA that can't follow directions?

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post #20 of 150 (permalink) Old 7-9-2010, 2:21 PM
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Re: Fog's Air box Mod

The results should be the same, yes.
post #21 of 150 (permalink) Old 7-9-2010, 2:36 PM
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Re: Fog's Air box Mod

ok just making sure I didn't need to change my label

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post #22 of 150 (permalink) Old 7-13-2010, 6:29 PM
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Re: Fog's Air box Mod

can i do this with just the stock filter
or should i just get the aftermarket, idc i was just wondering if i could
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post #23 of 150 (permalink) Old 7-13-2010, 6:40 PM
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Re: Fog's Air box Mod

Works fine with the stock filter. Of course if you want to buy a K&N know that they are now an official sponsor for AMA flat track racing


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post #24 of 150 (permalink) Old 7-13-2010, 10:13 PM
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Re: Fog's Air box Mod

Turning out my pilot screws to 2.75 worked best for my bike. You might want to experiment with that a bit.
post #25 of 150 (permalink) Old 7-14-2010, 10:08 PM
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Re: Fog's Air box Mod

Quote:
Originally Posted by roxynoodle
Turning out my pilot screws to 2.75 worked best for my bike. You might want to experiment with that a bit.
And here I had better results with 2.25 turns.. But I wonder. I know it isn't the best test. But I had a higher top speed with that, than 2.5 and 2.75 turns. the richer it got the smoother the power felt, but... The less power it felt. Is there a good way of telling, without pulling plugs right after the engine is cut on a WOT position... If I am running too lean? From what I can tell, power pretty much increases up until 10k then slightly falls by 11, which should be normal for a red line.
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