For the legal stuff. I, RSWarrior, Yamaha, or anyone assumes liability for this modification. If you choose to do this modification I have no responsibility for the outcome that may happen to your bike.
Since that's out of the way now. I will start by saying I am not mechanic, tool and die maker, or any real type of authority on fabrication or motorcycle parts of any kind. What I am is cheap. I looked at the Thunder Manufacturing Hurricane intake, and love the looks but do not like the price. I have experience from some years ago modifying Volkswagens and have put cold air intakes on my cars. I decided after doing some research and seeing what others have done, to attempt my own DIY Hurricane intake. I am frankly not sure if anyone even cares, but I thought I would post it for the 2 random members that have asked me. If you have any questions please feel free to ask me. I have no real performance number or dyno results. But the butt dyno seems to show a small gain.
Most of these parts I got from my local Autozone, but most auto parts chains have the same stuff. Most of the parts I used can be swapped out for anything similar. If you do not have an Autozone local to you and want to follow my same footsteps you can order them from http://www.autozone.com/ I have included the prices and part numbers for ease of ordering.
Parts needed:
1. Yamaha part# 4TR-1440G-00-00 JOINT, AIR FILTER ( I included the parts micro-fiche -- part number 18 below.) I ordered mine from the local stealership for about $13.00. I have seen them cheaper online.
2. Spectre / 3 in. dia. 90 Degree Chrome Elbow Intake Tube Includes Collar Clamp-Part numer 8698 -- $10.99
3. Spectre / 3 to 3 or 2 1/2 in. Black Air Cleaner Tube Coupler and Reducer-Part number 8771 -- $7.99 Autozone
4. (1) 4" Hose clamp -- About $1.50
5. 1" x 1/8" Aluminum Bar stock -- About $4.00
6. Spectre/Small White Cone Air Filter - Part Number 8168 -- $21.99 Autozone ( Any conical type air filter with a 3" inlet will due; depends on your taste and budget)
7. (2) Small self tapping screws. The shorter the better
Tools Needed:
Allen/Hex Wrenchs, Phillips Screwdriver, Saw (any kind really), Drill, Drillbits, and wrench or socket and ratchet for mounting bolts.
1.Start removing the 2 bolts on both sides of the right side airbox. I cannot remember the size.
2. Remove the Gas Tank (I am not going into depth on this since there is a lot of material on this on this forum.)
3. Loosen the hose clamp that attaches the air snorkel that runs from under the tank to the right side air filter housing. Little Allen wrench
4. Remove the whole right side air filter housing
5. Remove the rubber air snorkel piece that is connected to the top of the right side air filter housing. I wish I had a techinal term, but after checking the Yamaha Micro-fiche, they do not have a part number or name for it. It is glued into the inlet and you have to give it a good tug. Then, inside the rubber snorkel there is a rubber gill running through the middle of the snorkel (where it attaches to the stock Rt. side air filter housing); you will need to cut out about an inch of that gill.
6. Take Yamaha part# 4TR-1440G-00-00 JOINT, AIR FILTER and you are going to have to cut off about an inch off the top so that the joint fits snugly into the stock air snorkel.
7. Next you are going to fabricate a support bracket out of the Aluminum Bar stock. I did not do a very good job on this, but I can always make a better one later. Measure the distance from both of the stock mounting brackets that the Rt. side air filter housing attaches to. From that measurement, you will have a basis to start fabricationg your support. (it's the silver bar in the bottom of the pic below)
8. After cutting the bar stock to your chosen length you will have to drill four holes in the support. One on either end of the bar to use the stock brackets that the Rt. side air filter housing attaches to. Then drill two holes to screw the bar to the back of part# 4TR-1440G-00-00.
9. I spray painted my support black, but you can finish to your pleasing.
10. Attach the support to the back of part# 4TR-1440G-00-00
11. Attach the stock air snorkel off of the Warrior to the part# 4TR-1440G-00-00 and attach it to the inlet that the stock snorkel was removed from. Make sure to use the extra hose clamp you purchase here to attach both snorkel pieces. (In my pics I did not, but I made sure that the two snorkels fit really tight.) This is also a good time to plug the air vent outlet on the bottom of part# 4TR-1440G-00-00.
12. Attach the Support bracket using the stock bolts you removed from the Rt. side air filter housing mounting
13. Attach the 3" to 3" plastic/ silicone coulper to the hole on the part# 4TR-1440G-00-00. Make sure to tighten the hose clamp snugly since this is one of the main stress points the whole intake is pulling on.( Sorry I forgot to take a pic of this step). The bright blue tape was placed there to prevent scratching the cylinder heads while mounting the support bracket.
14. Attach the 3" 90 degree elbow to the other side of the coupler.
15. Attach your conical air filter to the elbow using the supplied hose clamp.
16. Put your tank back on. You may want to bump your ECU or adjust your mapping . I use the DIY ECU adjust since once again I am cheap.
You're finished and now have a DIY hurricane Intake!
***I did not like how far my Hurricane intake stuck out so I did cut about an inch off of the elbow where it attaches to the snorkel, and about another inch off of the coupler. But this is personal preference. ***
Please notice there are different filters in the different pics. I was able to locate the smaller white filter at Autozone and that is the filter I gave the part number for.
Good luck to you...
Just remember if Yamaha really is dumping the warrior in 2010. Then we all have a collectors bikes now...