Let Your Engine Breathe
VStar 1300 Airbox Modification
Long before the commercially made air boxes were available I wanted to get more air into my motor.
After removing and examining the air box on the bike I decided it might be a fairly simple thing to drill
some holes in the front and/or rear sides of the box.
I didn’t want too large a hole since water sprayed from a wet road or rain might enter the box and possibly block the filter.
I decided that 1/8” holes would be small enough that the surface tension of water would preclude its entrance.
That seems to have been proven in real-life testing.
The air box does have a drain hole in the bottom in the unlikely event a small amount of water should enter the box.
This, of course, could be enlarged if desired.
Some people have drilled large holes in the engine side of the air box. I don’t like that idea for two reasons:
1) it brings in hot air from between the two cylinders and
2) a large hole has a greater potential to let water in.
OK. Now that we’ve decided to drill some holes, how do we make it look decent?
I decided to create a template. I use Microsoft Visio for most of my drawings,
so that’s what I used to create a drill template. Here’s a link to the template:
Just print the pattern on your PC, cut it out, and tape it to the front of the air box (remove the box first).
Trying to keep the center punch in the center of each circle on the template, center punch each hole.
I used one of those spring loaded punches that you just push down on and Wham! it punches a hole.
Next, remove the template and, being careful to line up the drill with the center punched indent, drill the holes.
When you get a little tired and start to get careless with the placement, take a break and finish later.
You can also relocate the template and drill even more holes.
Put the air box back together and go ride. You’ll be amazed at the improvement it makes.
JackK
Drilling The Stock Exhaust
You do not have to remove the muffler to drill the hole but it does make it somewhat easier.
Beg, borrow, buy, or steal a 1-1/4” to 1-1/2” hole saw. Be sure to get the one that is rated to drill metal.
The ones for drilling wood may not work and might break or burn.
You will also need a 12” extension for the hole saw. The extension will enable you to reach the baffle with the hole saw.
Take the muffler off by undoing the clamp at the front, where the two pipes are siamesed into one, just after the oxygen sensor.
Then undo the two allen bolts on the mounting bracket at the back side of the muffler near the wheel and slide the muffler off.
The hole is drilled from the outlet end.
Stand the muffler on end with the clamp end sitting on a block of wood.
Then, if you shine a light down the center pipe, you can see the center baffle.
Chuck up the extension in a hand drill and secure the hole saw to the other end of the extension.
Insert the hole saw into the muffler until it contacts the baffle.
Drill through the baffle and remove the hole saw.
If you removed the muffler you can try to shake the cut off piece out of the muffler.
It doesn’t matter if you get it out right now or not. Replace the muffler.
Start the bike and rev it up slightly. The cut off piece of metal will come flying out the back of the muffler.
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